There is a challenging issue I’ve been trying to solve for some time now. To best describe this issue, I’m providing a few screen shots of what I’m trying to achieve.
The first image shows two flat pieces of plywood with identical thicknesses. Now, if I were to intersect these two parts (one having a protrusion), and I asked Rhino to Boolean Split, the results would equate to what’s shown in the second image: an angled cut. This doesn’t help me when designing templates for my laser cutter. My laser only cuts in one direction — down.
In the third image, you can see the ideal result. The intersecting portions of the one piece of plywood is given an opening that allows a physical union at an angle. This means the opening in the second part is cut in the direction of the laser… or in the case of Rhino, the opening is created in the direction of the extruded axis.
For me to make this part, I have to perform a boolean intersection of one part, explode it, delete all but one surface, extrude that surface to the original thickness, perform the boolean intersection again, delete all but the second surface and then extrude that surface back to the original thickness.
Is there no other way of doing this? This method is insanely time consuming if you have 4 sides intersecting and you have to figure out what part overlaps into which.
Any advise would be appreciated.