Hi Jim, do you have some example files with the problematic booleans that you could post here or e-mail to me at moi@moi3d.com so I could check them out?

One thing that can help is to avoid making a flow where the deformed result just barely skims right along some overlapping surface area on the target object, make the cutting object sunken down a little bit into the base plane so that it pushes some distance through the other object rather than just barely skimming it.

- Michael