You are saying "so now i am creating a program that will create new surface data off the stl within tolerance"__
If you find a solution plese post it.
I need myself help on converting stl to surfaces, so far I had been using Geomagic Studio 6 and a software called FreeForm by Sensable it work...
Same thing just happend to me yesterday, try this to resave the file, if you still have the file place it back where it used to be, same folder. I know this works for sure. Also you can attempt to create a dumb file save it with the same name as it used to be and same folder. This should work...