Cura missing large support area

[bertho 6]

Another strange problem:

I successfully printed a large oblong tray, about 180 x 70mm and 19mm tall.

Using Win-7-64, Cura 15.02-RC2 and the Ulti-controller. For appearance the convex side was printed up so it needs a lot of support. Zero problems with Cura.

On the same tray I added four small mounting studs and a 3mm hole.

The CAD model looks perfect.

The view in Cura looks perfect.

But----

When slicing it in Cura a very large 60x60x60 triangular area inside the upside-down tray is missing the support. One node of the triangle is near the 3mm hole.

I have spent way too many hours trying too many things without success.

 

• I tried Cura 14.09 on another computer.
  
• I tried a repair in an old NetFab.
  
• I exported the SolidEdge file as STEP and then imported it back to SolidEdge and then again converted to STL. I was hoping that the conversion process would throw out some artifact that might be causing the problem.
  
• I exported the SolidEdge file as IGES and then imported it back to SolidEdge and then again converted to STL. The IGES importing has options for healing STL files and I enabled all of them.
  
• I turned it the concave side up.
  
• I rotated it 45 degrees on the UM table
  
• Many more tries and variations of the above.
  
• I removed the hole in the CAD file. The support structure changed but is still way wrong.
  

 

The 3D rendering looks perfect. It is just the support structure that is wrong. It is hard to fix the CAD file if it is that is wrong when it visually looks perfect.

It is difficult to explain and visualize the error so I linked some pictures.

Here is the SolidEdge original file, STL, STEP, IGES

http://www.Vinland.com/images/temp/Bertho's%20support%20problem.zip

Hopefully someone can figure out what is wrong and how to avoid it in the future.

I am out of ideas how to fix it. I can always use the old version without the hole and mounting studs and glue in studs and drill the hole but that is not learning what is wrong.

Please take a look and let me know your suggestions.

Bertho

 

[Daid 306]

Most likely it's not your fault, but Cura's fault. The support code is currently a weakness in Cura, and can fail at random sometimes.