How to transform a multi surface part into a machinable solid (STL)?

 From:  simba
6833.4 In reply to 6833.3 
Hello Michael,

with one exception it would be best for me if I could set "solid at all times" in combination with sweep and blend and work with booleans. Is that possible? Maybe I missed a basic setting?! There's only one hollow/surface part in my design. I tend to work/end up with a mix of solids and surfaces.

Some of my 'boolean union' attempts lead nowhere after 15+ minutes processing time in order to create a solid part for machining purposes (on a current i7 with 32GB Ram).

S