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Face of body 3D prints in non-uniform fashion

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autocadFH8KR
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Face of body 3D prints in non-uniform fashion

First, let me apologize for the size of this project.  It was born of modifications to existing STL files; the original project was not available to me.

In the attached project, there is a component called Housing Bottom LUVNASP1.  Within that, is a body called Housing Bottom.  To overcome some printing challenges, it was necessary for me to move around sections of this body, so I broke it into four pieces (call them top, Top inner, Bottom inner and Bottom.  Then I swapped top inner with bottom inner and recombined the body into one.

 

All well and good, it did what I wanted... until I sent this to the 3d printer (via File / 3D print, save to file... and then sliced in my external slicer).  It all prints OK, but what I did find odd, is that those sections of the resultant model are  laid down independently of one another by the slicer (implying that somehow the slicer seems to detect that these sections are separate, though connected).  I haven't come out with a clear picture showing the final result, but it can be seen in the slicer first layer in the attached screenshot.  (I've also attached the resultant .stl file.)

 

For future reference, have you any idea what steps I should have taken to prevent this unexpected result?  (I have now selected the problem face of that body and press-pulled it, first expanding by .1mm, then reducing by .1mm to hopefully make it uniform.  Will not be able to try printing this in the next few days.

 

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