Ok thanks
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Alright, so.........took a look at the model to see what's up. I basically went about it as if I was preparing to print it myself, using what software and tools that I have. Here's what I've concluded:
The problem is in two parts, really. There
are errors in the main helmet, netfabb shows small holes along where the faceplate meets up. Even after repairing it, netfabb still shows the warning icon saying there's a problem. I've noticed that sometimes when netfabb alerts you of errors, printing anyway results in a good print. You see, most slicer programs will
try to repair the model, so the repair that netfabb couldn't seem to execute may be in fact applied in another program.
When I pull the "repaired" model into sli3er, it comes up just how you showed me. It has all kinds of weird holes, and will not print right if you try it that way. The problem here is sli3er itself. Sli3er is not perfect, and with troubled meshes it can be useless sometimes. This is one of those times.
When I pull the "repaired" cuts of the main lid into Simplify3d and Cura, it looks fine. The software is definitely reporting auto corrections, but they seem to be applied as they should, and all looks printable. Even set up some supports in Simplify3d to see if all would slice well, and it did.
If at all possible, try a different software and see if it works. I myself used to use sli3er all the time, and have not once used it since acquiring Simlify3d. It's not free, but I tell everybody I can how it's worth every penny and more. You've never seen slicing speeds so fast! You know what I mean when it comes to slicing speeds with sli3er........ugh. I've had lid parts take an hour before with slicer, but with Simplify3d it usually takes
seconds.
Also, yes the faceplate is rather thick in the center. Originally, the idea was to better set it up for casting, making it thicker reduces the chances of the faceplate warping. In all honesty, I meant to do a thinner version, but lost interest when other modeling projects started taking foot.
Anyhow, keep it up. Would love to see this thing finally printed. :thumbsup