Hi Sharif, probably the easiest method is to do that outside first for both pieces.

I mean generate 2 non-hollow pieces and boolean union those first:



That gets the outside formed. Now to clear out the insides, in one direction that can be done by boolean difference with this inner curve:



And to clear out the other direction, make a mitered one-rail sweep of this inner curve and use that object as the cutting object in boolean difference:



- Michael

Hi Michael;

Thank you for your help!. Per your instruction: step 1, I created the outer solid for both pieces and union them. Step 2, I did the same for the inner solid. Step 3, I use the Boolean differences and I subtracted inner solid from outer solid and it worked (See Attached Image)

-sharif

A simple 3 big extrude

Then 2 Boolean Merge, then Boolean Union don't make the trick ?








http://moiscript.weebly.com/uploads/3/9/3/8/3938813/tubeintersection_pilou.3dm

Hi Pilou,

re:
> A simple 3 big extrude
>
> Then 2 Boolean Merge, then Boolean Union don't make the trick ?
>
> http://moiscript.weebly.com/uploads/3/9/3/8/3938813/tubeintersection_pilou.3dm

Nope, not quite - your version does not have all the interiors fully cleared:



- Michael

I have sent the file before the last boolean merging! :)

Select All / Bollean Merge and you will have your result! :)
(of course on killing the parts merged resultant! )

Hi Pilou,

> Select All / Bollean Merge and you will have your result! :)
> (of course on killing the parts merged resultant! )

That doesn't work for me, did you mean to post a different file?

- Michael

Sorry for for the delay! New process! :)
(from the original post 1)Select only the 3 internal or external sections

- Big Extrude them one by one with closed faces enabled

- Boolean Merge the upper one (and kill the part not wanted)

- Kill the 3 curves sections

- Boolean Union All

- Kill closed 3 faces sections

- Select all then Shell (internal or external : Normal/ Flip following first choice at the beginning)

Seems fine! :)
Pinky is original
Gold is mine! :)

http://moiscript.weebly.com/uploads/3/9/3/8/3938813/tubeintersection_pilou2.3dm

Hi Pilou, yup I can follow your latest steps. But the Shell function isn't very reliable for thickening surfaces with sharp corners so it can be good to have a different way to do it.

- Michael

All the roads go to Roma! ;) (or almost :)