For some extra info- I have tried my best to make a watertight Solidworks CAD model. Most parts were saved as Part files, not assembly files, and merged using the Combination feature. This saves the model as one solid body and no longer has features. I have merged parts such as the entire front suspension, a-arms, brackets, motors, etc… in this method to try and avoid intersections.
Then I proceeded to manually merge the STL files together (changing the names, no spaces, special characters etc…) such as Front and Rear suspension as well as the main roll hoop (because they should all receive the level 7-8 mesh refinement) as one STL file so everything can be selected in one click. I also made a master STL file, as many others have done, and simply added the Aero features to this.
this is the biggest intersection problem i have had. Its not really an intersection but the parts are so close to each other that the mesh thinks its one part and tries to close it. i am working on fixing this in the geometry but so far has not led to any failed meshes (until the last couple i have tried)
