Created attachment 373 [details] A simplified reproduction (TestGeometry.cc), an OpenGL screenshot, and an output extract. When placing a G4Sphere (or a G4Orb) inside a hollow G4Tubs, I get spurious warnings about overlaps. However, the OpenGL display clearly shows that, as planned, there is no overlap. A simplified example is attached, together with a screen shot showing that there is no overlap and an extract from the output log showing the spurious warning.
The error message is correct as the setup is clearly wrong. You're creating an empty tube, therefore the sphere must be placed inside the world, not inside the tube! i.e. replace: new G4PVPlacement( 0, G4ThreeVector( 0, 0, 0 ), orb_log, "Orb", tube_log, false, 0, check_overlaps ); with: new G4PVPlacement( 0, G4ThreeVector( 0, 0, 0 ), orb_log, "Orb", world_log, false, 0, check_overlaps );