Alternative to MeshUnion (contouring, other)

I have a model made up of hundreds of meshes aggregated together. They currently exist as individual closed meshes.

I want to find a way to clean the interior geometry to get a single shell (what MeshUnion should do, but it almost always fails).

I’ve been thinking that contouring the meshes and unioning the regions could be the best way to do this. However, I have voids that, on some slices, are enclosed, so I’ve been contouring, making boundary surfaces, and unioning the surfaces so that the interior voids don’t disappear as they would in a region union. (Basically, I tried to recreate Rhino’s .slc export, because its boolean processing keeps failing, too.) But, the boundary surface and planar union components are failing on everything but the simplest meshes.

Is there another way to get these unioned regions?

I’m open to other methods of “cleaning” as well, but voxelating is also crashing before reaching sufficient fidelity. Shrinkwrapping loses the voids. I’ve tried MeshUnion preceded by various remeshing procedures (Pufferfish, Blender). Slicing with Termite/Droid (crashing). I’ve checked that my meshes are all valid and closed.

I can’t create the model another way because it is a required project methodology.

Please share the file here, or an online drive.


Need to see the mesh. If the calculation is heavy please use Datadam.