Boolean open mesh union failed

I have four meshes, and every two adjacent meshes share a common boundary curve, as shown in the attached figure. I used the mesh boolean Union operation to combine the meshes, but instead of the union, it made the meshes disappear.

Resulting mesh union:

I expect the normals are opposite on those meshes. The DIR command will show the normals for each. If you FLIP one of them it may work.

Having many overlapping faces is sort of odd as that can be very difficult to calculate as to what to keep. Normally using MeshSplit and then joining might be used to get these meshes to work together.

Can you send us the file with the two meshes?

Hi Scott,

I have attached the file, where there are two pairs of meshes, and each pair has a different outcome for the union.
mesh_union.3dm (3.0 MB)

Thanks!

your issue is that the edges do not really coincide, that might look like that from afar, but in fact zooming in a bit closer you see that they even overlap on the bigger surfaces, on the other one they are slightly closer but still too much apart.

also, dont use boolean operations on open geometry like that, you would use regular Join followed by Weld if you want a continuous mesh. but for this to happen here you have to model more precise.

generally, must you model these with mesh? why dont you just outline the curves and make a nurbs surface, what is your further goal?

below you see how the bigger surfaces overlap, if they get within a certain tolerance than you could try repairing it with MatchMeshEdge but i would not fiddle around with this at this stage, just rebuild it.

In this case offset with thickness would make the interestion better

Thank you for your response. I would like to use the combination of these two meshes as an input for my simulation. My project is focused on CNC machining, where I am seeking a tool and its trajectory to create a specific surface.

ok, but rebuilding it with nurbs to match your exact geometry is not very difficult in fact a matter of a minute. you then can still convert it to mesh for any kind of simulation if needed.

anyway if you want to proceed with meshes you would have to see to it that all the edges coincide precisely enough for joining.

btw this join+weld method works well in my case.

ic, so i guess the geometry which you uploaded was just a quick sample, so all the fuss for nothing. you are welcome

just in case anybody encounters such a situation with such crappy geometry like here, you can also use SetPt along the fractured seam, select all the close vertices and call the command in repeat, that would be a bunch here but its done in 1 minute so doable, then you can join and weld.