Thanks for the replies. It looks like setting External Thin Wall Type to Perimeters Only fixes this.

I've tried to find a setting that eliminates this issue. No luck so far, but changing extrusion width has a significant effect. I normally use 0.72 (with a 0.6 nozzle), which results in many "extensions," but at 0.6 there are only a couple. Attached screen shots show the same model, sliced with iden...

When I slice the model shown in "trailing-edge-rough" with different settings (for a different printer and material), the edge comes out smooth. So it may be some S3D setting or combination of settings? The attached factory file "trailing-edge-smooth-2" has the same model used in "trailing-edge-roug...

My parts have a fine vertical edge, and I just started to experience this problem. It may be model specific, as it shows up on some models and not others, but the models seem fine. Interestingly, it's happening in both S3D 4.0.1 and 4.1.2, but differently (the extensions are in different places when...

S3D-Jake: Any update on this issue? It's still occurring for me (with certain models), and I have to revert to S3D 4.0 to slice them. Thanks,

Don

Yes, having the same issue as SteveIsHeer. It looks like the workaround noted at the thread above, with a third process that's just a diaphragm, does the job, but ... yikes. There has to be a better way.

+1 . Would really like a non-clunky way to have solid layers between two processes. (It's not clear to me why the top / bottom solid layers specified in a two process setup are ignored.) This third diaphragm-only process concept seems like it's going to work, but wow that's an awful workaround.

I figured out that if I turn on generate support material, it's able to slice the model. It doesn't appear to actually insert any support material (and I don't want any), so in this case it's an acceptable workaround.

I'm having the same issue in 4.1.1 (Mac). Prepare to Print, and then it stalls while "looking for overhangs..." I'll try to attach a factory file.

I'm having the same problem, also on a Macbook Pro. Historically haven't imported profiles much, but now that I'm trying to do so, it isn't working correctly. I've gone to the extent of removing all profiles. It seems only the first one I import is saved correctly. Subsequent imports just take the s...