Hi Chris, what meshing parameters were you using to generate the STL file?

I did actually test generating an STL file from the model I posted, and it read into Rhino and verified that it read as a completely closed mesh.

But maybe some particular meshing parameters that you are using is creating some problem in the mesh, it could be that you are getting some areas with too many vertices being packed together, making the RP house's analysis tools think that they are all lumped together instead of being distinct. If that's the case then you may need to make a somewhat slightly looser mesh instead of an overly dense one.

It's hard to know exactly what you are running into though without some very specific information - please post your scaled model file and also give me the exact parameters that you are using for producing the STL file, that way I can generate the same STL file over here and examine it closely to see what might be going wrong.

- Michael