I work in the automotive industry, and I when customers send us their part data it frequently includes a complete rendering of the speaker grill, thousands of tiny holes included. This is awful to work with, and will often slow our machine design to a crawl. We only ever need the b-side of the part and the general contour of the a-side, and in the past we have either used a copy-surface+untrim surface+thicken to eliminate the problem geometry without actually harming what we need to work with, but it frequently does not work, and at that point we basically have to suck it up and deal with it. Has anyone stumbled across a method that would allow them to easily patch up such a surface?
Side note: when offsetting a surface I frequently see an error message informing me that the surface is not connected, even when I am only offsetting one surface. Has anyone come across a way to bypass that issue?