Bevel modifier breaks smooth?

[Thomas Hock]

Edit: No need to read this post, I misunderstood the problem

@Martin Bergwerf 
I think I found a Way how to select all Zero-Faces.
As their one common thing should be that they have no Volume/Area, creating one and then select Similar Area should do the Trick. (To then delete them and merge Verts by Distance). Apparently “quad” Zero-Faces have a lower Volume/Area than “tri” Zero-Faces though so we need to play with the Threshhold a bit.

Add a Cube/Plane, extrude one Side but rightclick right away so there is no visible Extrusion but Verts laying on top of each other (connected by Zero-Faces).
Then go into Face-Mode + Xray-Mode to select the Zero-Face(s) just created. With the Face selected as Active press Shift + G and select Area. Change the Threshhold to 0.000001. That should select every Zero-Face.
It worked in my Tests but I don’t really have a File which has those natively (afaik) so if someone could varify if that way works, that would be nice. Also see if the not mergable Verts even Merge afterwards. Because if not then it does not make sense to select and delete the Zero-Faces anyway.

[Martin Bergwerf]

Hi Thomas @Nokota ,

I have no problem Selecting all Zero Faces; just click on Zero Faces in the 3D Print Toolbox.

The problem in Neale’s file, is that Merge by Distance doesn’t seem to work.

Dwayne @dillenbata3 ,

The fact that Clamp Overlap creates Zero Faces is something that sounds very likely. I might not have tried Applying the Bevel and then Merging…That should actually work, because the Weld Modifier (after the Bevel) does the same thing, basically…

[Dwayne Savage]

Was just learning some new tools and found this. In edit mode, select all then click mesh->clean up->Degenerate Dissolve. This removes zero area faces and zero length edges. I just thought I’d share what I just found. 

[Martin Bergwerf]

Thanks Dwayne @dillenbata3 ,

unfortunately, for some reason, that doesn’t work in Neale’s file. That is one of the things that make it weird. Although it does work after Applying the Bevel Modifier (as you suggested). But the 3D Print Toolbox already gives us loads of Zero Faces even before the Bevel…

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