Hi Paul - for now, if you send the curves of intersection between the two bits, that might be worth a look.
OK, never mind I see your file!
@Paul_Bundarin - for a repeated pattern like this, I would work with one repeat. I see one potential problem … can you send me one repeat of the green decorative pattern?
If you don’t mind me asking, why do you need these two objects to Boolean? If your target is 3D printing, then this might not be necessary. Most 3D printing software just wants closed (e.g. solid) objects.
The printing house I have always worked with, Shapeways, only prints one object per file. But since this file is way over their maximum size, I have been looking into other options. Their prices have always been the most affordable. I know you cannot endorse anyone but any suggestions for an affordable nylon printing service would be appreciated!
Most printing services have a file size limit, so unfortunately that will be a problem anywhere you go.
If overlapping objects are contributing significantly to the file size it mat be possible to import the mesh in Netfabb to join the objects so redundant surfaces are consolidated.
You should be able to get a free Netfabb trial through Autodesk.
If the mesh file is 65Gb, I expect that will be a very slow process, or perhaps not succeed.
I’m using an older version of Netfabb and my experience has been with files under 10Gb