I have a relatively simple model to which I've added a lot of modifiers in blender. When I export to an STL the result has several solid layers that aren't visible in blender. I It also thinks that some areas are filler when they should be empty. The blender file is also showing as solid a feature (Axle drive) that I intended to cut of the edges of the enclosure.
My blend file https://drive.google.com/file/d/1XEmOR5hM-he4SAkGam6e8ZCfvHgDv1s-/view?usp=sharing The resulting STL file https://drive.google.com/file/d/1S5uGJHNUtQJroOG6Ug1dv5IFhWZa3VEE/view?usp=sharing
I have checked for non-manifold edges, merged by distance, recalculated the normals, etc. Any idea how to get an STL that matches my model?
UPDATE: To simplify troubleshooting, I am focusing on just one mesh. I started with a plane and built it up to function as the main enclosure. It is made up of only 81 verticies and 57 faces. The 3d-Print toolbox says that 46 of those faces are zero faces. I have been trying to figure out what that means and how to fix it, but I can't figure it out.
I'm not sure if this is impacting the STL slicing, but that's one problem I'm trying to figure out right now.