So, taking the above into account, if your Boolean operation fails, the first thing you should do is check the intersection of the objects. Select your objects and call Intersect. First, look at each intersection curve on the screen. Does it look correct? Are there any visible gaps or extra segments or other things that look strange?
If so, find out why. The resulting info box should tell you all you need to know about the curve. Does it say the curve is open? Then thats your problem area. More than one curve? You need to find out why there are either gaps or overlaps in your intersection. What causes gaps or problems in your intersection?
There are many possibilities. Some are due to modeling errors or inaccuracies. Normally this will correspond with one side of the gap. Zoom in closely and see if you can see the gap on the screen. Why is there a gap there? The intersection may cross a gap between surfaces, and that will cause an open curve. If you have forced together your object using JoinEdge , that may also happen, even though the object says closed. The other thing to check is your modeling tolerances see Understanding Tolerances.
If they are too large, this may prevent the intersector function from finding a complete intersection, even though all else is well. Try tightening your tolerances and running the Boolean again.
Once you get a full closed intersection, your operation should work…. Get the best intersection curve you can and try editing it until you have a closed object. You may need to add or change a segment, do some point editing, take out overlapping segments, or something like that.
Once you have this curve, you can try trimming your objects individually. You need to explode your polysurfaces to trim with the intersection curve. Coincident seams — All objects have seams. Sometimes when the seams on two objects are at exactly the same place, Rhino has trouble with the intersection. Solution: Either try to move the seam, or try moving one object just a tiny, tiny bit if you can without making your model inaccurate.
Or try to do the operation manually. This is a fairly common occurrence. Avoid building your model this way if you can. Solution: As above, you may move the object slightly if possible. If not, you may have to do this operation manually. Nearly tangent surfaces — Like the intersection of two equal diameter pipes at an angle. I drew up a new mould block shape and it worked fine this time. I hope to get this cut out on a CNC mill this week! Angry Bird stab mould v2. Hi Andrew- I was not quite sure, in the earlier file, what was supposed to happen along that slot at the trailing edge- the main surface did not, quite, reach all the way to the slot.
At any rate, I would ExtractSrf the vertical walls of the slot and run DivideAlongCreases both options set to Yes to split up the surface into a polysurface, then rejoin it all to the main object- meshing will work better, possibly other things as well, depending on that happens next for this part.
OK great, thanks Pascal. The slot trench just needs to sit adjacent to the trailing edge, to give a defined corner. Why 3D Modeling Boolean Operations Fail One of the primary reasons that Boolean operations fail is unclear design intent in the way the tool and blank the input bodies are combined.
These errors are possibly the result of earlier operations, or small errors when translating modeling data, for example: Short edges and sliver faces Huge tolerant entities and collapsed features Improper intersections Near-coincident entities Near-tangent interactions Complicated intersections The figure below shows tolerant vertexes as indicated by the sphere , enveloping a short edge.
Large Tolerant Vertex The tool yellow and blank cyan shown in the figure below have almost coincident faces. Ambiguity in Coincident Faces Generally speaking, Boolean operations do not make assumptions regarding the model by definition —they are precise operations that make no attempt to infer design intent in an imported model.
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