S3D 4.01 skipping/omitting parts in prints

[MvM]

First of all, I like Simplify 3D a lot. It maximizes my control over my printers to get the best results.
However, I am having troubles with models where Simplify 3D V4.01 just seems to skip on parts on otherwise will leave openings in prints that should not be there.
In most cases, I just resort to Cura to print them and this has worked out fine every time.

Last week I had such a case where a batch of parts I printed for a customer were missing a small edge at the end of the print. S3D simply did not print it.
Now I have another example: A lightweight drone frame designed by a customer simply won't print correctly in S3D.

As you can see in the pictures, S3D will not continue the outside layers and/or not fill in the space between them.
I have tried every setting combination I could think of

Shell: Single Extrusion Walls or Perimeters don't matter.
Infill: Perimeters Only, Single Extrusion Walls or Allow Gap Fill, it will still not connect the outline correctly.

Same STL-file prints fine with Cura, even the old version that I have.

[MvM]

Here are a few more examples.
None of the options I tried would let the parts be connected.

Why won't S3D at least print ONE single complete outline so all parts are connected??

To be sure:
- Print nozzle: 0.4 mm - Automatic print width
- 2 Shells
- 30% infill (not that that matters in such thin parts)
- 35 mm/s speed

[rrdavis]

Can you attach the STL file? From the photos, it looks like there may be some issues with how the 3D model was created. Should be pretty easy to confirm with a copy of the STL file (or you can use the Repair checks in S3D to check yourself)

[dkightley]

What would be even more helpful would be to create a factory file......File menu==.Save Factory file......and attach that to a post.

We can then not only see the stl file....but your settings, which will need some tweaking to get a good infill.

I'm guessing that a combination of using the Separate Connected Surfaces option and tweaks to the infill settings will be needed.

[MvM]

I don't have S3D available at the moment to create a FFF-file.

But I have included the STL-file.

I have noticed that on many occassions, Simplify will not show a solid 'look' the model loaded when Cura does not seem to have the same issue.
When this happens, I often will do a repair through the Netfabb website to get the model 'fixed'.

[airscapes]

You would need allow single extrude wall and allow single extrude fill.. can also play with the perimeter overlap percentage
Not sure how strong that would be, maybe some issue on how the model was made? Can you post an image of how this looks when sliced but whaterver other slicer you say has no issues?

This is with the above settings using v4.0.1

[myprinter]

If looking at the stl in Meshmixer or running some Repair_detect in S3D you see error in the stl. Maybe that is the real problem.