Hi Michael, I doubt that a boolean union at high density would be workable. The geometry would be in too many little tiny slivery fragments which is not a good situation for booleans.

Is it possible for you to post the .3dm file for your original screenshot or a similar test case? Is the path planar or 3D? Are you using any specific options for the Array curve command, like Rotation: Flat maybe?

I think that you might want to start by generating some boundary curves maybe by arraying a point object placed at a corner of your original profile.

The process might be something like array one point , use the plugin to export points to .csv file, then use the plug-in to import points from .csv file making a curve. That's what I would try out if I had an object to test with.

- Michael