Glad I could help!

edit the process, advance tab, top left uncheck the stop printing option. Check out the docs on how to use this feature as well as grouping process

Advanced tab, change from gapfill to allow single extruded fill and see if that removes the gap fill Zigzags

I have several parts I sell that slide on a machined rod that contain round and rectangular holes. To get accurate fit, round holes must be .45 mm larger than the rode within the model. At least with the way I calibrate my machine. With a smaller nozzle and extrusion width, the less the difference. ...

I would suggest you reprint it with cura and see if it is as nice as it was before. Almost looks like a mechanical issue rather than software.. Then again, I did not upgrade S3D and can not say for sure as there are apparently still many issues with the current version.

Not really . Depending on where your holes are you could make a separate process and have more shells but that may mess up the outside look.
I have use insert with only 2 shells and 50% infill without issues. Make a small test model, you can also remove the inserts so you won't be wasting any..

Onshape is fairly fast to lean but not really made for making game players or D&D models.. Mechanical part YES, artsy stuff, no..

Hey "G" check you post over at MG I posted some different models to use for setting the EM and starting height. An also referenced this post
viewtopic.php?f=8&t=13746

Speaking in terms of S3D 4.01 Nozzle diameter set to actual nozzle size (.25) Extrusion width set to auto for now. Once you get it working you can set it smaller if needed Extrusion Multiplier .. for my setup would be someplace around .90, I would print test squares to determine exact setting Filame...

Very interesting and fits with what i have seen found over the past year. I switched to a 2 wall square which I use to verify starting height and to some extent Extrusion width (should be .2 or .3 larger than the model. Then print a different model that is just a 30x30 square 2 layer high of my chos...