Boolean union fail despite intersections test pass

Hi
V5
Boolean fail, no doubt co-incident faces, the brown was created using the lines of the green.
I tried for intersect and black lines show all edges intersecting, or so it seemed.

If I explode and join the faces then all is good., no naked edges etc. I get a solid.

Are all CAD progs blessed with this situation if the cause was abutting faces and no overlap ?

If we cannot boolean with abutting faces, why not an option to merge faces by a given tolerance amount, or use project tolerance.

What is correct procedure to boolean union these two solids ? Is it better if possible to explode and join ?

boolean fail yet intersections all.3dm (268.5 KB)

Steve

“despite intersections test pass”

What does this mean?

Here’s the thing, I know you’re read it here before: Boolean operations with coincident surfaces other than planes tend not to work.
In this case, all you need to do is extract the coincident faces from both objects, and Join the rest. Done.
boolean fail yet intersections all_PG.3dm (149.2 KB)

-Pascal

Hi,
yes as I suspected, though I got the name wrong, now corrected co-incident surfaces.

“despite intersection test pass” was me running intersect command on the two solids to see where they came together incase there was a gap etc, but the result showed no gaps.

Method noted, extract co-incident faces.

There are times though when the objects are not so straightforward a shape and for a little overlap the boolean is the easier quick union, if only there was a way of choosing an option to overlap enough to see acceptance by boolean, the faces that were causing the problem.

Steve