Re: OpenSCAD STL export may not be fastidious enough!
That may help in some cases but the problem, as I understand it, is that OpenSCAD computes the model in higher precision so the conversion to float to make the STL needs to be topologically aware. That would mainly be removing degenerate facets I think.
> I've noticed that some of the 'watertight' STL files produced by OpenSCAD aren't considered to be 'watertight' by some other programs:
Do you have the .scad files used to generate those STLs? They could provide good test cases for future enhancements.
I don't think binary STLs would make a difference in these cases, but but if you're interested in pursuing that train of thought, it shouldn't be hard to hack in binary stl support in OpenSCAD for testing.