I would readily blame the 3D carving for the problem as well if it were not for a few things. It is foam, that is already cured and dimensionally stable, carved on a well calibrated industrial 5 axis mill, all of the vertical dimensions are correct, and i have dozens of other things carved on this machine from cad data without any appreciable measurement inaccuracy. It’s only the things that are sourced from this scan data.
It just seems like the software reads planar data extremely well, but if you present it with data in the form of a column like structure, it isn’t exactly sure how thick the column is with respect to the height.
And the data is good, I only wind up with a single chunk after processing without having to do any manual align.