Hi Scott - can you post the 3DM model file with the particular curve in it that does not form a solid when extruded?
Normally just the number of points by itself should not make any difference for making something a solid or non-solid, but if it has a malformed shape like any little area where the curve crosses over itself in a small curly-cue type thing, that could do it.
It could be possible that after doing a rebuild, the rebuilt version doesn't have the problematic shape in it. That's my best guess without being able to see the actual curve.
Or another possibility is that it's just very slightly non-planar by some teeny tiny amount.
It's not necesssarily needed to rebuild everything automatically, it kind of depends on the situation. Usually one of the main reasons to rebuild is to eliminate excessive _segmentation_ in curves where they're made up of many separate pieces which then generate multiple faces, not so much for reducing point count alone unless the curve is pretty messy.
Rebuild can actually increase the point count in several situations if you have a very simple curve to start with.
- Michael
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