Try grouping your Blender meshes so that they export to one file.

You'll need to enable advanced flex options. That will switch on a help link to explain what to do next. If you need help with that stage please ask on a modelling forum.

The compiler is Studiomdl, anything else is a third-party GUI wrapping around it.

Hmm, you're right, it's only when the bone and the mesh share the same name. This must be related to the way that DMX stores both meshes and bones in the same hierarchy.

Either way, I'm confident that this is a bug in the compiler, not the exporter.

From testing the compiler's behaviour, of course. I just made a test plane with 36 bones and it's mashed up too. If you want to upload your blend I'll take a look and see what's different about yours. Perhaps it's a bug that has been fixed in the version of the engine you're compiling for?

That's not a message I'm familiar with. Are you trying to do fancy stuff like delta animations? Post your QC please.

This is happening because her face is weighted to too many bones. The limit is three in Source 1, and four in Source 2.

I have code in the exporter to cull the excess links and redistribute their weight across the survivors, and I'm sure you've noticed the warnings. But that isn't enough for your "head" mesh because even though the individiual vertices are within the limit, the mesh overall is stil weighted to too many bones. 11 bones, to be precise. Evidently the engine doesn't like this.

You need to convert the face bones to shape keys until the head is within the limit. You should be fine once it's just the head, neck, and possibly jaw bones.

I'll add an error message to the exporter to explain that the model is invalid.

No idea yet. Please upload your blend.

Your links are broken.

Looks like a misplaced bone. Have you tried re-exporting the animations like I suggested? In particular anims\ragdoll.dmx.