Power Booleans has a powerful and flexible Mesh
creation capability. If it starts
with a closed NURBS PolySurface, it will create a Closed Mesh without cracks
that
is suitable for Stereolithography and other Manufacturing applications. It
utilizes a different
approach than that used by the native Rhino Mesher and in some cases produces
superior results. If the Rhino Mesher is unable to produce a STL compliant
mesh,
try the Power Boolean Mesher. If the Rhino mesh produces too many polygons
or
self-intersecting polygons, the PB Mesher might be able to give you superior
results.

Select the "NURBS Booleans with Mesh Result" to utilize the Power Boolean Mesher.

Here is a mesh with a Maximum Angle of 30 Degrees
and a Maximum Edge Length of 3.0.
Note that fillets done using the NURBS Boolean are maintained.

The Power Boolean Mesher does an excellent job of
producing low polygon count meshes
suitable for game developers and other high performance graphics applications.
This case
shows a mesh with a Maximum Angle of 60 degrees. It produces a mesh with
520 vertices
and 564 polygons. The same angle in the Rhino Mesher produces 874 vertices
and 667
polygons.

Here is the same NURBS object meshed using the
native Rhino Mesher. You can see below
in the shaded images the visual quality of the Power Boolean mesh is better
around the small
holes.

Rhino Mesher results with 60 Degrees. Note the
problems near two of the holes.

Here is the shaded image of the Power Boolean Mesh.
Note the superior quality of the small
holes and improved fidelity of the revolution surface.

Adding a Max Distance To Surface of 0.5 improves the
quality of the mesh without a large
increase in the number of polygons.

The Power Boolean Mesher can also produce very high
fidelity meshes suitable for applications
such as CNC manufacturing and Stereolithography. Here we have used a Max
Distance To Surface
of 0.01 with a Maximum Edge Length of 0.5. The image below shows the
quality of the final rendered
image.

Rendered image of the high fidelity mesh created by
Power Booleans Mesher.