This is quite old now, but recently I was playing with a different project and believe that I now understand what was causing my trouble back at this time.
On the physics object (e.g. a ball Blueprint actor) the following worked well:
- Enable CCD
- increase BP_Ball > Physics > Position Solver Iteration Count
- increase BP_Ball > Physics > Velocity Solver Iteration Count
The settings I was using satisfactorily in my test project were: Position Solver Iteration Count: 10 and Velocity Solver Iteration Count: 2
It should be noted that computer spec will play a significant factor in what settings work well. Lower spec machines may require higher settings to avoid skipping a physics interaction test at a crucial moment. As far as I understand it, these settings control how regularly the position and speed of the object are tested and the physics interaction calculated. So the frequency is too low, your ball may pass through an object rather that bounce of it or something like that.
thecodermarcelo 's comment above is on the money although I haven’t played with trace complex yet. I will do so.
I hope this helps someone else! 