Faces after knife project tool

Hi all. Im having a bit of a nightmare with a project im working on at the moment. I have used the knife project tool to cut a pattern out of another mesh. I seem to get this weird thing where the face of a mesh has its center point out side of the cutting zone and its causing all sorts of problems when i apply a sub surf modifier. Any ideas how i can fix this?

Thanks in advance

That’s never going to take a subdivision surface modifier well. You need quad based, fairly clean topology to get predictable results out of subdivision. Model it more like this and then shrinkwrap onto the other mesh (or snap points of the new mesh onto faces of the old while actually building it)