@adamjames95 wrote:
Hi @Anonymous ,
I created a YouTube video demonstrating the latest way to resolve this (linked below):
Hope this helps!
https://www.youtube.com/watch?v=_zy7LYrrpfI
-Adam James
This isn't "the latest way" to resolve that error and quite frankly your tutorial is outright misleading.
First I believe you should explain the reason for that warning message.
When you import a .stl, by definition of that data format it includes a triangulated mesh. A triangulated mesh is one way to represent 3D geometry. Triangulated meshes have a finite resolution and no topology (in a mathematical sense)
That finite resolution is the reason why most CAD software including Fusion 360 does not natively use meshes to represent 3D geometry (for design input) but uses NURBS / BRep. Those are mathematically precise descriptions of geometry with theoretically infinite resolution and models built with them have topology.
Meshes, are computationally simple. NURSB/BRep on the other hand are not. When a .stl is converted directly into a solid body, every triangular facet is converted into a 1-degree (flat) NURBS surface.
That alone will create a very "heavy" and computationally intensive model.
An egg shape, for example can be represented by a single NURBS surface. If you create a cylindrical hole though that egg, CAD software has to calculate two trimming loops where the cylindrical surface and the egg shape intersect.
However if that egg was converted into a .stl file and that was then directly converted into a faceted solid, now CAD software might have to calculate a few hundred NURBS surface intersections to create that hole and also has to store many more trimming loops in memory. That is very computationally intensive and to make users aware that warning message exists.
There are at least two main avenues a user can now explore if a solid model is desired:
1. Reduce the mesh density. That usually results in a large loss of detail and the end result is usually not very good!
2. Re-mesh the .stl into a quad mesh and convert that quad mesh into a T-Spline solid. I created the tutorial below a number of years ago to show a few techniques:
https://youtu.be/aMZKgzBpodI
In the tutorial I used a few other software packages to get to an end result. I used InstantMeshes to re-mesh the objects. By now Fusion 360 has a built-in method with the organic mesh conversion. This requires a paid subscription:

However it is rather slow and there are a good number of other options that can help. ZBrush and 3DCoat have industry leading re-meshers. Blender has a marching cube and quadriflow remesher. I belive an InstatMeshes plugin exists for Blender. The Lab tools in SideFX Houdini also include InstantMeshes.
Remeshing complex, triangulated meshes is really the latest and greatest method to covert complex triangulated meshes into solids.