Consider this (below)… The four white boxes are split by four blue planar surfaces into three pieces each. The Srf SL cluster (from my toolkit) returns the largest one based on sum of edge lengths, Those four largest pieces are joined into a solid brep (magenta colored miter box, green group).
Your model is different, of course, with intersecting boxes having various angles from vertical and not being square, so corner cross-sections may not match? Is that why you are using solid difference?
Depends on how you made it. Somewhere in there putting that object together pulled the edges out of tolerance. The file tolerance is 0.001 but the edges are out by almost 0.05. So some operation allowed that out of tolerance to happen - like suspending the absolute tolerance when joining. However, not having made the thing, I cannot tell you where in the process that happened. But most likely somewhere in there you or some component you used introduced that error. - as it’s almost 50x the normal.
The only way to know would be to have a step-by-step procedure of how to make one of the frame elements that are out of tolerance.
This is a somewhat elaborate effort to intersect, trim and combine four overlapping breps to make a shape similar to yours (without the holes and bumps you have). There is a text panel list of “Angles” that apply to each side and the ability to have a trapezoidal (non-rectangular) shape.
The white boxes are created in the teal-colored group (top left) but could be created in other ways. .The outward faces are used as the basis for PxS(Plane Through Shape) cutters used to trim the breps. Then Cap Holes and SUnion are used to make the final shape (Closed Brep, green group).
Thank you Joseph! It works perfectly. I have learnt two new commands Pxs and SplitMulti
How do I make those little buttons describing Grasshopper commands in the message?
