Is there any way to add "mouse Ears" to help prevent corner curling. basically a small 1" round Grim at certain corners.. it would be a great addition to S3D, to be able to manually place these on our models, like we currently are able to manually place supports.
I have already made that suggestion and after a bit of discussion I realised that an explicit "mouse ear feature" is not really required. What would be very useful, though, is the ability to tell s3d that a model should not have its perimeters merged with another model if they touch. At the moment if you add mouse ears to a model then when it is sliced the perimeters are merged and so when you break the mouse ear off, it rips the side out of the thing you've added the mouse ears to. By having the ability to say "don't merge the perimeters" then the ear models and the model being "eared" have their own perimeters and those perimeters just butt up to each other and less damage will result when the model is de-eared.
I simply use a hobby knife to slice off mouse ears instead of breaking them off.
However, I have broken them from time to time and generally I don't have problems with them breaking the actual print. It sounds to me like you may have a separate issue with layer adhesion if the mouse ears are strong enough to separate model layers.