Hello,

The last scan mesh I imported into Rhino (a few days ago) was around half a million polys. Using a combination of T-splines and VSR Shape modeling I was able to take that very organic 20MB surface and end up with a watertight STEP file around 340K in size with deviation of less than .1mm, well within tolerance for the application. I would not recommend using the technique indicated earlier in this thread, that just leaves you with a jumbled mess of control points, highly unmanageable. Using a combination of submesh creation and proper T-splines and VSR surfacing tools will leave you with not only a much cleaner and lighter set of surfaces, it will allow you to modify those designs more easily.