Hi Brian,

> Michael
> Is there any reason why this array will not booleen join please?

There's a few different problems in here... Like Pilou mentions, you actually have some duplicate objects that are stacked up right on top of each other, that definitely won't help. Actually the top one seems to have 3 copies stacked on top of each other.

Also like Pilou mentions, having the "end seams" of the surfaces all in one area will just magnify the difficulty for the booleans to figure out which piece intersects with what...

Like this end:



That's quite a number of edges all sticking kind of partially through each other... Things like that will cause difficulty for the booleans, as it progresses piece by piece, each piece will tend to create little tiny slivers where these things kind of barely graze by each other.

Also some of the pieces are not quite aligned in a fully symmetrical way, like here:



One piece seems to be sticking out a bit more, if you have more precise regularity to the pieces it would probably help.

But you mention that you want to boolean it from a sphere?

Please take a look at Danny's illustration here: http://moi3d.com/forum/index.php?webtag=MOI&msg=1792.12

Building the sphere in one segment first and then replicating those grooved segments will be a far more robust way to create that kind of thing because it will avoid this kind of "barely grazing" type of curved overlaps that cause problems.

- Michael