Hi niko, it's because the larger shape is itself not a closed solid, it has an opening in it.
If you select that part, note that the object type indicator reads "Joined srf" and not "Solid" like it would if it was a fully closed object:
Running the script that selects naked edges shows 4 edges that are unattached:
The naked edge script is useful to set up as a shortcut on the N key so that you can see where the unjoined edges in a non-solid object are at. To set that up put in the following script as the command part of a shortcut key:
script:var gd = moi.geometryDatabase; gd.deselectAll(); var breps = gd.getObjects().getBreps(); for ( var i = 0; i < breps.length; ++i ) breps.item(i).getNakedEdges().setProperty( 'selected', true );
Those edges seemed to be slightly out of the 0.005 MoI join tolerance, so I scaled the object down by 1/10 in size, separated it into individual surfaces, then joined those, and that formed a completely closed solid, then I scaled it back up again.
I've attached the result here as union_fixed.3dm - now with both those objects as fully closed solids the boolean should work as expected.
- Michael
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