Hi Stefan, thanks for posting the file and the video. I am able to reproduce that bug over here now - it seems to be due to the intersected solid being malformed probably because of those doubled up faces. The object ends up with a broken region where the "is void" flag is set for both the exterior and interior regions, and when MoI goes to write an object it wants to go through the solid (is void == false) region but doesn't find any solid pieces.
It looks like it's not just File > Export that fails, File > "Save As" doesn't write the intersected piece either.
So it seems that the bug is in the boolean intersection calculation but it will be difficult to fix because booleans can get confused in general when an object has self intersecting pieces...
A couple of tips from the video - if you want to show only the one named object a shortcut for doing that is to go its entry in the scene browser and right-click on the eye. The right-click on an eye hides everything else other than that one object so that saves the step of separately hiding other things.
Also when you do a boolean you can just do it using the rectangle curve, the booleans will automatically extrude it out as needed during so you don't have to extrude it as a separate step, unless you want to make it go to a limited depth instead of all the way through.
- Michael
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