Can't fix non manifold edges

ARTa10.3dm (5.2 MB)
Hi, I am new to rhino and grasshopper and having problem with getting fine mesh.

I am trying to boolean union these cubes and 3D print it, but I can’t get a good result.
No matter what I try, I get an open mesh or closed mesh with non manifold edges.
I tried mesh repair, weaver bird join and weld mesh, mesh mixer, manual deleting of naked edges…

The cubes are put slightly overlapped to make intersections, but it that’s the matter it’s mo problem to
relocate them.

Thank you in advance!

First, I’d ask why you want to boolean these? 3D print applications handle overlapping solids without issue, usually.

Beyond that, I’d say that simple shapes like these are way easier to work with as nurbs vs meshes. In fact, try selecting them all and run toNurbs on them all (deleteinput=yes), then run MergeAllFaces. Save your file in between - you may run out of memory. Once these are nurbs, they boolean just fine.

Hi Peter,
Thanks for the feedback.

I didn’t know that 3D printers handle that!

I understood nurbs are more convenient than mesh when it comes to boolean operations!

I just didn’t know such basics you mentioned. That helps a lot.

I will try those method you mentioned and let you know the result.

Best,
Kenichi