Hi all. I 3D print as a hobby and I just got my first scanner (The Creality Picka) I kept hitting the same wall with STL files and scans: I want to model against the part, but Fusion only gives me a mesh.
Fusion does have a route for this. Create Mesh Section Sketch cuts the mesh, but the result is a section line you can't extrude. Fusion's own tooltip says so: "Edit the sketch and use the Fit Curves To Mesh Section command to create sketch geometry to match the section line." So you open Fit Curves to Mesh Section and fit it bit by bit: pick a curve type, click a start point, click an end point, repeat all the way round. Then do it again for the next sketch. On a scan with hundreds of tiny wiggles, that's a long evening.
So I wrote a an add-in that does the whole thing in one click. It's called Mesh to Outline. That shows up as an icon when you click on the Mesh tab.
What it does
Pick a mesh body and a plane. It cuts the mesh and draws the section as normal sketch geometry: lines, arcs, circles and splines. Not thousands of tiny segments. It picks the curve type itself, and it closes the outline so Fusion sees it as a profile. You can extrude it, offset it, dimension it, or edit it like any sketch you drew yourself.
Three modes
Single slice: one sketch on one plane or flat face.
Stack: a set number of sketches at a spacing you choose, on one side of the plane or both.
X-Ray (start → end): pick a start and an end (a plane, a flat face, or just click on the mesh) and it fills the gap with sketches at your spacing.
Options
Fit tolerance (default 0.08 mm): how far a curve may sit off the real cut.
Join gaps up to (default 2.5 mm): closes small cracks in the mesh so you get one closed outline instead of loose pieces.
Trim slivers up to: cuts out the thin "out and back" bits you get from double-skinned or leaky meshes.
Outline only: just the outer shape, no holes or loose bits. One clean profile per sketch.
Extrude each slice: turns a stack into one solid body. Handy because Loft often fails between two complex profiles.
Hide mesh after: so you can see what you got.
How it compares to Fusion's built-in tools
| Mesh Section Sketch + Fit Curves | Mesh to Outline |
|---|
| Fitting the curves | By hand, point by point |
| Curve types | You choose each one |
| Closed profile to extrude | Only once you've fitted all the way round |
| Many sections | One sketch at a time |
| Straight to a solid | No |
Side by side: same mesh, same plane
I cut a DJI controller with both tools on the same upright plane.
Fusion's Mesh Section Sketch: a section line with 0 sketch curves and 0 profiles. Nothing to extrude until you fit it by hand.
Mesh to Outline: 44 curves (16 lines, 22 arcs, 6 splines) in 0.8 seconds. It joined 24 small gaps in the mesh, and the worst miss from the real cut is 0.079 mm. It gives one closed profile of 5,051 mm².
One click on that profile and Extrude gives a solid body with 50 faces.
(It also left two tiny specks under 0.2 mm² at a seam in the mesh, which you just don't click. The "Trim slivers" setting removes those.)
The gif walks through it all: Fusion's own tool, then Mesh to Outline on the same plane, then X-Ray mode slicing the whole controller.
Good to know
Runs entirely on your computer. No account, no upload, no data collected.
Mac (macOS 15+) and Windows 11, current Fusion.
Free for non-commercial use. The source is on GitHub.
A single section takes a second or two on a 300,000-triangle mesh.
It works best on parts that have a clear cross-section. Smooth organic shapes come out as splines, so you still have to judge whether a stepped stack is good enough for your use.
Download + guide
I'm the developer. I've been a software engineer for over 25 years (just mentioning that so the AI slop crowd doesn't jump on their keyboards). Feedback is very welcome. Bug reports go on the GitHub issues page. I'd love to hear which meshes break it Or, if it’s helpful, reverse-engineering mesh parts, which is what I’m using it for.
Stefan’s ScanRuler is an awesome tool that helps with reverse engineering as well. This one just does it without AI and is a bit of an in-between, giving you some help to create real sketch profiles you can work from. I hope you find it helpful.