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rhino:jbbooleanfix [2015/09/14] (current)
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 +====== Fixing Boolean Problems ======
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 +Here's what I do when someone sends in a Boolean problem. -JB McNeel Tech support
 +
 +First I check the Units and tolerance setting compared with the geometry in the file to make sure there isn't a major scaling problem. ​ Assuming the units are right, I verify the tolerance is at least 0.001" or 0.01mm or perhaps one order of magnitude higher, particularly for small parts with tiny detail. ​ If the settings are wrong, I make the changes; scaling geometry if needed, explode and rejoin to make sure I'm working with solids. ​ If not solids then I check the surface normals with the Direction command and fix any that are pointing the wrong way.
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 +Next is to run SelBadObjects and make sure there are no problems with the curves or surfaces. ​ If there are, rebuilding edges, detaching trim curves and retrimming almost always fix the problem. ​ Once in a while I'll have to delete and replace a surface but that's not often.
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 +After that I run the Intersect command between the two solids and see if I get closed curves that clearly define the trimming and joining boundaries. ​ If the curve it open, I inspect the surfaces and see why.  Most of the time when the intersection curves are sorted out the Boolean works. ​ Occasionally even with good curves the Booleans fail.  In that case I do the splitting, deleting, and joining myself to get the same result that the Boolean would have produced.
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 +That's the process. ​ Give it a try.  You will very likely discover the problem and fix it in the process.
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 +If any of this is confusing, read on.  The information and detail on the following pages is excellent. ​ -JB
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rhino/jbbooleanfix.txt ยท Last modified: 2015/09/14 (external edit)