Thanks again guys,
I started a new project and added only the outline, and it fails to export, 3d viewer and dsn export works just as before
Kiki: I have the same settings as you, but with the endpoint merging option enabled, with an error setting of 0.1 in this case. This means that all points that are within 0.1mm of each other will be merged.
Sprig: I enabled outline mode and verified every arc and line, they have the same start and end coordinates down to rounding of the last digit displayed in kicad, i.e. +/- 0.000001. I checked the source code for kicad2step, and two points within 0.0001 of each other are considered to be the same. I see absolutely no reason to why this shouldn't work. All coordinates are double precision so they should be fine.
kicad2step does post logs with wxLogMessage( "%s\n", ostr.str().c_str() ); but I have no idea on how to access that from the kicad ui, i tried running kicad2step.exe in cmd but that gives me nothing at all either.
I tried to upload the DXF file containing the outline, but since I'm a new user I'm not allowed
Should i report this as a bug ?