Boolean union doesnt work, although Intersect works ?!

Hi all,

I can not BooleanUnion these 2 simple breps. I check the Intersect and it gives a curve as result, but why I can not Boolean Union thess 2 breps ?

boolean problem.3dm (2.0 MB)

Thanks!

you have some tolerance issues here:

you can use the curve from intersect to trim the top surface, delete the lower surface of the top part and join.
but this will not give you a nice result.

did you import the data from some other program?
strongly recommand to remodel the 2 curves with proper fillets, extrude and booleanunion…

kind regards - tom

EDIT:
further digging:
i did not check the angles … see @Gijs post.

make sure the radii are proper 2.00 and 3.00 m
also consider cutting the notch later.

ok - with the info of Gijs - remodel everything with boxes is quite straight forward:
_cplane … set a custom rotated cplane
_bounding box for upper / lower element
_setPt (y of the custom cplane for the common / coplanar faces)
_box for the details
_boolUnion / Difference with mergeAllCoPlanarFaces
_filletEdge

make sure to set proper Radii especially the one i marked here:

boolean problem_remodel_tp.3dm (2.5 MB)

hope this helps - kind regards - tom

Just a FYI: the sides are not square, e.g:

has an angle of 89.971 degrees

and these are also slightly off parallel:

I second @Tom_P ‘s advice to rebuild these shapes from scratch.

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