Topsolid Wood Crack Repack Better

Open the Advanced Crack Fill dialog. Most users ignore the "Substrate Layers" dropdown.

To repack better, change the Substrate Orientation from Auto to Perpendicular to Main Grain. topsolid wood crack repack better

Why? TopSolid tends to fill cracks with a material vector that matches the board’s length. This creates a weak "bridge." By forcing perpendicular repacking, you create a cross-grain locking geometry. When the CNC cuts this, it feels like solid wood, not epoxy. Open the Advanced Crack Fill dialog

The Scenario: A 2-meter walnut slab with a 12mm wide bark inclusion running 800mm down the center. The Default Result: TopSolid crashed on "Boolean Union" three times. The crack repack created a 0.5mm thin wall that shattered during machining. Here is the proprietary sequence that TopSolid power

The "Better" Repack Result:

Here is the proprietary sequence that TopSolid power users are adopting. This assumes you are using TopSolid'Wood 7.14 or newer (2024/2025 editions).

If your tolerance is set to 0.01mm, the repack will take 4 hours. If it is set to 0.1mm, it takes 4 seconds.