Aberrant slicing behavior

[jamsessionein]

I have the following model that I'm trying to slice:

http://www.fusedcreations.com/adam/badge_fix.STL

Renders fine, I've run it through Netfabb and it doesn't catch any problems, everything seems welded and fine.

When I tell Simplify3d to slice the model, I end up with weird missing planes:



The missing planes will sometimes vary when I hit the "prepare to print" button without changing anything else about the model, but I have no real explanation for it. For example - same model, same settings, different holes:



What am I doing wrong here?

[jamsessionein]

Apparently turning the model 45 degrees on the bed makes the surfaces all slice properly. What on earth?

[jimc]

i have caught 3.0 doing dome odd slicing behavior myself. very strange unexplainable stuff like your talking about. there seems to be no consistency with it so i have not been able to send anything to s3d. not sure if its a model issue or not. netfabb says its all ok.

[JoeJ]

I've had plenty of models that Netfabb said were okay that still had tons of errors in them. For this part, it looks like you have a lot of self-intersecting surfaces. Perhaps the entire part is just a bunch of individual planes that overlap?? That's definitely going to cause issues with the slicer since it isn't a true 3D solid, it's just randomly intersecting sheets.

FYI - version 3.0 added a new check for this, so you can go to Repair --> Identify Self-Intersecting Surfaces to highlight the problem areas.

[jimc]

i had another situation of odd slicing behavior last night where s3d was tossing solid bridging layers in where there wasnt supposed to be any print at all. i finally managed to catch it, verify the model was good and get consistent bad results with it so i saved the factory files and pictures and got it to the developers. not sure if its the same issue as the OP but just wanted to give an update on this so everyone knows that they now know about it and that the issue hasnt gotten ignored.

on another note, if you run into this you can easily work around it by just adjusting the layer height .01mm at a time until it goes away.