Don’t rely on Chaos.
In .27 Chaos, sure. It works. But with enough breakable objects in a scene it crashes.
All that Chaos does (I say all, but it’s a good amount of stuff when you do it manaually) is to grab a mesh, in engine, and break it apart based on whatever you manually choose.
The texturing isn’t perfect when it does this. But it does create manifold geometry.
The asset in the scene automatically breaks apart as it’s pieces are set to simulate physics.
You can do the same thing in blender.
Take a cube, fracture it up, uv map it correctly. Leave all the pieces in place so the engine assembles it for you.
When you import the mesh, it will import as a bunch of separate pieces.
Dragging the pieces in the scene will retain the cube shape.
Setting all the pieces to simulate physics will cause them to correctly simulate (assuming they have collision enabled properly).
Given all of that. Once you make your models you can simple swap out the single mesh for a bunch of mesh parts that share the same location as the original mesh.
The parts will then simulate as you’d expect.
With a little of work you can turn this into a reusable blueprint that will always work no matter what.
Instead of Chaos, which until it is finalized will always cause issues.
(I would suggest going with an array of static meshes for the replacement parts. Though it is a bit complex to setup. Maybe a pyton script to select a folder and automated the array population would help).
Making the geometry break correctly in blender can be challenging, but it doesn’t have to be.
Just be mindful of the UVs…