Issues Creating STL for Shapeways

[bwterrainforge]

Hello,

I have been making models for shapeways for a few months. Lately I have been experimenting with new sprue designs to cut down on costs. I found a new plate style sprue that cut my proce in half and made one model successfully.

I am working on the second model and I keep running in to issues

Shapeways keeps flagging the mesh as

• Model failed during repair.
• Model is not manifold.

I followed the instructions I found on https://www.shapeways.com/forum/t/rhino-stl-problem-how-can-i-make-shapeways-accept-my-model.583/

CheckMesh
CullDegenerateMeshFaces
ExtractNonManifoldMeshEdges
ExtractDuplicateMeshFaces
UnifyMeshNormals

Using ShewEdges does not highlight any naked edges.

Here is a link to a test file of the design

sonsOfOmega-shoulderPads-test.3dm

you will find the the original solid as groups, then the original as booleaned solid, then the whole sprue and cluster separate, then boolean, then finally converted to a mesh.

What am I missing?

[DiegoKrause]

the original nurb model have some trimming problems.

if you extract the surface and use DupBorder you can run _CurvatureGraph to check and find the issue

[bwterrainforge]

thank you Ill take a look