This plug-in sounds a little too good to be true. Converting a mesh
into a NURBS solid is usually seen as a very high-end application and
the programs I am aware of (GeoMagic Studio, RapidForm, Surfacer,
etc) all cost over $10K. What I might suggest is to purchase Smurf, a
Rhino plug-in that I have heard good things about. However, Smurf
only works with Rhino 2.0 at present. To produce a NURBS solid from a
mesh is a tedious and labor intensive process best avoided if at all
possible. The CAM program I use (VisualMill) works just fine with stl
meshes so I can mill or RP meshes, but have to use a different
program to edit them. The good news is that in version 4 of Rhino,
you may be able to work with meshes with the same features as the
All in all, most of the plug-ins available for Rhino have nothing to
do with the authors of Rhino (Robert McNeel & Assoc.) and they are
presented on Rhino’s web site as a convenience. I suggest creating a
Customer Review describing your experience.
On the other hand, Booleans can be very tricky. Coplanar faces can
occasionally cause Booleans to fail. Tolerances can sometimes be
adjusted to allow Booleans to work (try first tightening tolerances).
One thing you might consider to reduce polygon count in your meshes
is the program Decimator from GeoMagic. It is a wonderful and
intelligent piece of software that reduces polygon count with a
minimal affect on the overall shape of the mesh. I have reduced
polygon count up to 75% and still produced a good useable mesh that
is much easier to work with.