Delete Duplicates, Stitch Seams, Ultrazoom
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This could belong in Wish List, but there may also be some procedures I haven't tried.
I was modeling on a circular floor plan with radially symmetrical features. Many of the features were mirrored and rotate/copy to multicopy them. Unfortunately, in the process of working with a circular floor plan, I had to regenerate the circles, making sure that I used the same segment count. Well, even so, the new circles for whatever reason did not register exactly with the previous circles. This created additional intersections of overlapping circle segments. It even seems that multiple planes were created with microscopic vertical displacements in the Z axis, because while cleaning up the plan I had difficulty in zooming in close enough to discern inference points and large areas of the floor disappeared while editing, so that I had to do some reconstructive knitting.
As a culmination of experience over a measly year and a half, the features in the subject header would certainly be nice to have in SU. These are available in Blender, if you want to go there.
SU needs a duplicate cleaner or a decimator, a seam "stitcher" where you can select "heal to the left, heal to the right, or optimize to center all along the gap, and some way to zoom a whole lot tighter to inspect tiny, microscopic unfilled triangles and such which are created by using some of the more popular plugins.
And then, someone will reply with a way to solve all of the above. I even expect to be corrected on my still rough workflow issues. Bring it on, guru. -
now theres a challenge.
Hard to say how feasible it would have been without seeing your model, but i think a lot of your problems could have been solved with some constructive grouping.
As for the circles not lining up, if you make sure you always line your circles up to the same point in your model and always use the same number of sides you shouldnt have too many problems. The thing to remember here is that all geometry in SU is made from straight lines, so with your circle youve got to make sure all the lines match up.
A cleaning tool would be very useful, although i believe there are a few rubies that already do some of that.
A healing tool could be pretty dangerous in the wrong hands. I've got images of shoddy house models with thousands of healed faces everywhere...
And lastly, the zoom issue is a known problem called clipping. I think its something to do with openGL, although im very rough on the specifics.
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