Now, the exact same model sliced in Cura comes out perfect.
So I'm wondering what I'm doing wrong in S3D?
What could cause this?

http://cl.ly/3w0F3M1z3R0G/Image%202015- ... 8%20am.png

The photo should work now. It's not only the little hook in his head, but all the supports.CompoundCarl wrote:Well the photo you posted isn't working either, but I'll take a guess. Your factory file only has a tiny little hook that is above the build platform that could need support. The hook is only about 2mm wide, but you currently have your support pillar size set to 5mm! There's no way a 5mm pillar will be able to properly support that tiny hook. So change the support pillar resolution to 1mm and it will work.
This is explained a lot better here: https://www.youtube.com/watch?v=6tlrCpwAV4M