Thanks emanuel, I did a bunch of testing and seems to arrived at the same result.
So I saw you used Solidify to increase the thickness then fill as well. So without it, the shape in Blender will be 1 plane thin, then the voxelization algorithm seems to like to turn the entire shape into a solid. That seems to be the case for your shape as well if I turn off Solidify modifier.
If I conceptualized that correctly then for my next question of optimization is:
Is there a sure-fire way to select the "proper" thickness in Blender so that the resulting voxel will be one cell thick within my domain (aka as thin as possible), depending on my domain resolution of course.
So to keep it simple, if my domain cell grid in fds is .1m*.1m*.1m. Then setting the thickness to .1m would realize that right? Similarly if my domain is .5*.5*.5 then my thickness should be .5m? If there's no relation then is it a fiddling thing? Just have to keep exporting and check?
How about that "Custom Voxel/Pixel Size checkbox where you can also define 0.1m (or left unchecked). What's that option's relation in conjunction with thickness I feel like these two seem to need to be the same number.
Thanks,
Richard