Sorry for bumping, but I need some help.
The finished puzzle design is at 2.7 million polygons. In the STL options screen, there are 2 options that change the resolution. Angle and tolerance. What does each mean and what are the maximum values without affecting shapeways quality?
When you design something in Solidworks the model is essentially "infinitely precise" but you can never achieve this level of precision by exporting to a triangle-based format like STL. The exported model will deviate from the Solidworks design and Solidworks has two measures of deviation. The "tolerance" measure is how far a face in the STL can deviate from a face in the source model. The "angle" measure is how far an edge or vertex can deviate in angle / "sharpness" from the source model.
Shapeways printers just aren't that precise. The print process has a maximum resolution of roughly 0.1 mm for faces and the "angle" resolution of the printer is even worse. You can allow both to deviate a lot and still have a perfect print.
Another thing to note is that Solidworks isn't "smart" about which pieces deviate more or less. You can have 60 small triangle pieces on the inside of the puzzle each using 10,000 triangles and the core for the puzzle only using 5,000 triangles. If you want to cut down the triangles in a smarter way you'll need to export each piece type and control the triangle count for each. Then put together all of those exported pieces into the final STL to upload. Remember, the smaller the piece, the fewer triangles it should need.