to use _showEdges correctly - check the output in the commandline (not only the visual on screen)
to get consistent result in exporting mesh-Data, i recommend to run the “mesh” command,
check the mesh for defects (showEdges, Meshrepair, …)
export selected as binary stl.
to get more info, as Mitch wrote: post the rhino file and the exported stl.
if above tips already helped mark topic as solved / solution checkbox.
@pmonahan In addition to what Tom has posted, if you want to fillet edges that are connected with the same radius, fillet these edges all in the same FilletEdge operation.
Thank you, that looks great. I think what led me to the issue was as @Gijs pointed out; I did not fillet all of the edges in the same operation, which leads me to this @Tom_P, how did you undo the fillet edges in the original file? I thought that was not possible?
it s not undoing the fillet, it is more exploding / untrimming / deleting / retrimming / joining / combining the surfaces.
in this case it was easy / fast:
_explode
select the fillet-Surfaces - easiest in front view in this case
(selecting to much, unselecting the planar stuff to keep)
delete
_untrimAll
_createSolid
delete unneeded volumes