If you have it in the pre-unioned state and can send it to me, I can see if I can fix up the problem with the Union or what is happening there.
There was a problem in previous releases where if you used Union in a way similar to Join, that is to glue surfaces that share a common edge rather than intersecting with one another, that there could be some unjoined edges in the final result. But that should have been fixed up with the last beta release.
- Michael
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