in the attached I have a pattern that I have seen a number of times. I decided to save the example.
There are three polysurfaces. If I boolean union all three I get two bad surfaces.
But I cam do an extract bad surface and cap to get things back working. I am wondering why I get a bad surface in such situations that can be fixed so easily.
Yeah, that works - it’s a matter of tolerances I’d say - there are faces only .016 wide and file tolerance is, well, .003… I’d want more leeway than that - rule of thiumb is, tolerance 10x smaller than the smallest ‘feature’ . Edge tolerances on the small objects (What commandf) are right around .003
If you explode and RebuildEdges on the small object you’ll see some bad things -