I am happy to say that this issue has now been fixed with Version 4.0.1. I tested the large STL file mentioned at the top of this thread and it now slices and exports correctly. I was able to save several large 100MB+ gcode files without any issues. Thank you for reporting the issue and for bringing...

Just wanted to add a quick note to mention that this issue has now been resolved in Version 4.0.1. There is a more detailed thread with lots of additional information at the link below for reference:
https://forum.simplify3d.com/viewtopic. ... 975#p37809

Just to confirm, this issue has now been fixed in Version 4.0.1. Repeating the steps listed above now works correctly and has the expected result.

Thank you for the detailed report and for bringing it to our attention!

I am happy to say that this issue has now been fixed in Version 4.0.1. Thank you for all of the great information that was posted in this thread and for bringing the issue to our attention. You can download the latest version by logging into your account on the Simplify3D website and proceeding to t...

I am happy to say that this issue has now been resolved in Version 4.0.1. Loading large STL files or opening large factory files no longer shows the issue in the screenshots above. You can see other changes in this version at the link below: https://www.simplify3d.com/software/release-notes/ To down...

There will be an air gap precisely where the two processes meet. I can see the air gap ONLY in the slicer visual window after it was sliced, in reality, the air gap during the print gets closed up because of gravity. Just to let everyone know, Version 4.0.1 has added several improvements for multip...

After slicing there is a gap between the processes visible in the preview. This gap is also visible in the print. For Question #1, I wanted to add an update to this thread to mention that Version 4.0.1 added several improvements in this area. The software will now automatically ensure that you have...

If the S3D developers could snap their fingers and have things work as I describe, so you are free to pick whatever layer heights you want, and not have to tweak processes 2...N because you changed the first layer height of Process 1 I am happy to say that Version 4.0.1 made many improvements for m...

it would make zipping multiple processes together a bit easier. I am happy to say that Version 4.0.1 will now automatically ensure there is a perfect transition between processes, even if you are using different layer heights or other settings modifications. When setting up a print using the instru...

Ok, I will try that next time. It does seem like something that should be handled automatically though. Just to let everyone know, Version 4.0.1 will now handle these transitions automatically, so even if you setup a print as described above, there will be no gaps between processes. That makes it m...