Post by John Brookes transformMatrix.invert(); can sometimes give an identity matrix, happens when the matrix has no inverse. Its determinate =0. (Ithink) Now how to get round that not a clue. Apart from slightly move the offending vertices and hope random guessing fixes it :p
that is "same normals" case Ruben is talking about. so you either change normals (if possible in pv3d) or move vertices towards their would-be position in something that has nice mapping (such as sphere).