Hi Chris, it's also possible that you have created some details in this part which are just too small in relation to the resolution that the RP process can actually handle, like for instance here:






That's a little tiny fillet piece with a radius of 0.06, and that's actually from your previous model before any scaling down.

If you're then scaling down by a factor of 0.044, that's going to make that particular feature have a radius of 0.00264 , which is extremely small, probably quite a long ways beneath the actual resolution of what their RP process can produce.

Then since it is a curved surface it will get a bunch of smaller polygons generated in that area as well.


Such small features may be considered by their analysis software as being essentially collapsed together, which can confuse the analysis of the volume. If that's the case then it could be possible for them to adjust the tolerance being used in their analysis software to reduce it so that those things won't be considered to be lumped together. But it is also possible that you may need to eliminate these tiny features or possibly not use a tight angle value when meshing, to avoid this kind of problem of generating micro polygons that are smaller than what the RP house is expecting.

- Michael