Yes, even with fine approximation there might be gaps in your model where the round edges meet the trim surfaces. This seems to be an underlying flaw with the round operation in maya. I thought that it was just the trim and surface construction tolerences being too loose. But even at the tightest tolerence these gaps still appear.
I compared a simple model constructed in maya initially and then rounded in Maya & studio tools and rendered in Mental Ray with fine approximation so I could get a fairly objective result. The Maya round was generated at the tightest tolerence while I got 2 tolerences in studio tools (one at ProE settings and one at general CAD settings). The tight tolerence of ST is of course ment for producing solid stitchable nurbs for export to ProE which is a bit unfair to Maya so the loose tolerence is more equal to the tolerence offered by Maya. Here are the rendered results plus close-ups. (all including the close-ups were rendered at 1600x900 and resized to 640x480 for web)
Maya
Maya closeup
Alias ProE
Alias ProE closeup
Alias General
Alias General closeup
Even in the like-for-like comparison Alias seems to be much better. (Actually for production surfacing (not rendering) most of the rounding and blendings is done using UG or ProE, I remember the engineers I used to work with were always complaining about the accuracy of Alias rounds so we started doing all of that detailing in UniGraphics).
This, while it is usually not a problem for the likes of animation and such, is a big problem for high res visualization.
The question is, is there some way of getting the same results from Maya as Studio tools, and if so, how? Also, has the Nurbs engine been changed from that used in PowerAnimator (same as ST)?