How can I fix mesh distortion when converting a STEP file to STL in SolidWorks?

Hi everyone,

I’m trying to export a complex curved part from SolidWorks 2023 as an STL file, but the mesh gets distorted — especially around small fillets and curved edges.

Here’s what I’ve already tried:

Adjusted STL export resolution (fine/coarse settings)

Switched between Binary and ASCII formats

Checked part integrity and surface continuity

Even after these, the STL looks uneven when opened in Cura and Blender.
Has anyone found reliable settings or a workflow to get a clean, lightweight STL from SolidWorks without distortion?

Software: SolidWorks 2023
Goal: Prepare accurate STL for 3D printing

Thanks in advance!

1 Answer

hi There,

Try using Custom STL settings in SolidWorks. Set the deviation to 0.01 mm and angle to 5° or less. This keeps curved parts smooth and accurate. Also, use Preview Mesh before saving to catch any distortions early.