Hi Jonah, maybe what you mean here is that the underlying quad mesh (before it becomes n-gons) is not perfectly aligned between all surfaces?

By this I mean the quad "posts" that form polygons internal to each surface.

That quad structure follows the UV layout of each surface, so it isn't typically feasible to get identical quad structure between different surfaces that meet along a trimmed edge instead of along a natural surface edge.

Things like cylinders or spheres with symmerical cuts can often align along a natural surface isoparm, but when you just boolean 2 shapes together it isn't typical for the surfaces to meet at an isoparm.

It's basically the same problem as trying to reconstruct a complex model made up of booleaned parts by using only one single big untrimmed surface.

So certainly MoI's mesher won't do that, but every vertex on every n-gon there will be a matching vertex on the adjacent face though, making a "water-tight" mesh.

In the future there will be a few things I can do to increase quad-structure alignment in some different cases, like for fillets that have a plane on one side and a curved surface on the other side.

Doing all matching quads along every edge is a lot harder problem - it means creating a mesh that is not initially aligned to the natural UV grid of the surface, which doesn't really fit very well with some of the normal processes of surface algorithms such as splitting surfaces into smaller ones which has to happen along UV iso boundaries.

- Michael