Can't remove unnecessary Geometry in Object I want to make a 3D printed Marshall logo for my guitar amp, so i downloaded a Marshall font, extruded etc. and turned into a mesh.

When I had it in the shape I needed and edited the pins, I wanted to slice it, but the problem is that the overlapping lettes produce internal geometry that confuses the slicer.

Im new to blender, but I tried many ways to remove the geometry (booleans, intersect etc) but no tool works like it should.

I need something to create an edge at the intersecting faces to remove them. I even installed an addon for this, but nothing works.





I also think the whole geometry is mucked up, because the faces are ignoring the edges and go over them at some parts. I just dont know why its so mucked up. Is it because of the conversion from Text to Mesh?

Here's an example of the Overlapping



If it's too messed up, it would also be great to get a way to redo it properly. I started my first try with a vector graphic of the logo, but i couldnt get the conic shape of the text. With the font i just change the depth in the font settings and cut of the rest of the extruded material...

ah and here is what my slicer does with my Model:
I find this a rather unsatisfying answer, as it does not involve "proper" modeling, but a functional way to get an acceptable mesh for 3d printing (I think/hope) would be to bake a height map of your object, then use that height map to displace a subdivided plane.  This bypasses the problem of self-intersecting geometry because the height map is an undifferentiated mass of height data.



The crispness of your edges and the smoothness of your surfaces will depend heavily on how much you subdivide your plane.  It will also depend on the resolution and bit depth of your height map image, I'd suggest using a 16-bit file format.  You'd have to relate all that to your 3D printing methodology to determine whether you'll get an acceptable result.

Please let me know if you'd like a description of how to bake a height map or what I did in this particular case, my previous answer here has some info.

But as a general matter, I'd love to learn a more . . . elegant solution to the problem of self-intersecting meshes.  Something that doesn't involve a lot of manual retopologizing.