Wrap Solidify Too Smooth - Troubleshooting help

I work with extracting endocasts from skull ct scans. I have a protocol I follow that basically use wrap solidify with split cavities at 1mm. I pretty much do this every time with slight fluctuation with the split cavity adjustment. See pic 1 for my typical endocast:

you can see the lobes, and even some nerve tracks.

Today when I was working with this skull, and they are from the same batch of scan with the one above (everything remains the same, machine of scan is the same, same species, about same dimensions, etc.)

after 2 separate trials, I get this instead:

Things that I’ve checked:

  • voxel size and dimensions, the measurement is roughly similar with my other scans
  • surface smoothing is turned off, as I usually do in all my endocasts
  • I tried a couple times with no split cavities, with splitting it smaller 0.1mm and up to 2mm, all are either overflowing and with little detail or too small.
  • I also tried to grow the skull by 0.1mm and then try to wrap solidify, then try to grow the endocast back. Still little detail captured.

on top of this, the skull looks totally fine in details:

I’m just here to look for some advice and ways I can trouble shoot this.

Appreciate very much!

What is the exact voxel size reported in this scan versus the ones that worked well? It looks like there is too much smoothing at some point in the process. So you should try to adjust the kernel sizes based on the voxel resolution (not some preset value)

thanks for the suggestion, see below for the specs:

and here is the one that’s smoothed:

Although I did realize the better ones are done via version 5.8.0 and the smooth version is done on another computer that has 5.8.1. Is that enough to make any difference?

Thanks so much.