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Please see the .blend file attached.

I want to 'sweep' a profile along a path to create a solid that can then be exported as an stl file for 3d printing. Unfortunately, I have several issues...

  1. the ends of the resulting 'solid' are uncapped. While it's easy to select and alt-F the end vertices, it seems there must be a simpler way

  2. I construct the 'solid' using the bevel modifier. But, regardless of what method I use, I always end up with overlapping meshes - as highlighted in the following image. The resulting stl file has 'bad edges' and I think this may be a reason:

enter image description here

  1. Finally, the resulting mesh seems to have far too many faces, but I can't see an automatic way to reduce this. Again, this results in a large blend file and a huge stl file.

I know it's bad form to post multiple questions, but these are in a way all aspects of the same problem: How to construct a valid stl file.

Anyway, as always, any thoughts on resolving any of the above hugely appreciated.

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Let me unpack this one by one :)

1. Fill caps
You need to check Fill Caps in Geometry > Bevel > Fill Caps

enter image description here

2. Overlapping geometry
This is a result of beveling multiple curves into one point.
You'll have to manually clean it up, or use the Boolean modifier, etc.

3. Too many faces
To adjust the amount of faces change the values in Shape > Preview/render resolution.
You can do this for both of your curve shapes.

enter image description here

Here is the edited .blendfile

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  • $\begingroup$ I don't think my profile has any overlapping vertices. Can you elaborate !?! $\endgroup$ Commented Jan 21, 2020 at 15:49
  • $\begingroup$ Thanks - that's a huge help, and that definitely creates a printable file now, so while the overlapping meshes are still there, it doesn't actually seem to be an issue for the resulting file. That said , I'm still really struggling to see what was wrong with my geometry. $\endgroup$ Commented Jan 21, 2020 at 16:13
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    $\begingroup$ There were two free floating vertices, in your Bevel curve. They prevented the Fill Caps function from working properly. And also created more overlapping geometry. $\endgroup$ Commented Jan 21, 2020 at 16:23
  • $\begingroup$ How did you know/spot that? $\endgroup$ Commented Jan 21, 2020 at 21:34
  • $\begingroup$ It was just a lucky guess :). Good luck with your project. $\endgroup$ Commented Jan 21, 2020 at 21:39

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