I'm using blender to prepare a cosplay armor from a 3D model I have. The first part is to cut the model into pieces (e.g. a chest piece). Now this piece is just a "curved surface" (the original model is a solid object, I need to make a "shell" out of it).
To print the surface, I add some thickness to it. The problem is that adding thickness (using Add Modifier > Solidify) results in a mesh that has thickness, but is not good for 3D printing - it's non-manifold.
Here's a simple example. Consider this curved surface:
But if I want 1.5m of thickness: I would hope real solidify would close the cylinder part completely. Instead there's a negative inner cylinder within the outer cylinder. Needless to say, this can't be printed, you can't apply boolean modifiers to it, etc.
I can fix these issues using Blender's great 3D tools (I'm using Blender 3.0.0), but this requires a lot of work (Some of the meshes are quite detailed).
Is there a better way to add thickness?