Okay, I got it to work. I redrew the base part (inlet) and then I redrew the rib cross section. I extruded / Boolean diff / array circ. / Boolean joined.
I still had trouble with the Boolean diff.. The first time it didn't work. I tried it again but reversed the order I picked the solids and it worked.
Still not sure all is right ... but it looks good ... lol

Thanks for your time.

Congratulations!

Maybe there were some slight differences in spacings or something?

- Brian

Here is a quick video of doing a Boolean diff on this part. The thing to note is my cutting surface I made punch all the way out both sides of the object.



I think the issue you are running into on this part is in the little half arc cup at the bottom piece. The little cup part is slightly out from the top shape which is doing the "little sliver doesn't work thing."

If you open the part without rotating it, it's in the back side. You can find it by doing an extrude strait down of the top profile the doing and isect curve on the 2 solids. This will reveal little fragments that will show you what is being described.

The new "subset" booleans coming with the next v3 beta can help with this kind of stuff. It will let you get it done with just one boolean union since you can limit which faces are used to actually generate cuts. Some info on it here: http://moi3d.com/forum/index.php?webtag=MOI&msg=6663.1

The way it would help with this particular case here is that after you create a rib like this (it may be a good idea to try and reduce the rib to its minimal overall size like this, it just makes for a smaller amount of overlapping surfaces to be resolved), with it just sticking all the way through a ways:



Then you need to set up a face selection on the main object that leaves out the back side of the object, the easiest way in this case to do that is to go select the back faces like this:



And then invert the selection. Then with those back faces not selected a boolean union between that main object and the rib will generate this type of result:



It will basically ignore the back side of the object when doing the union, if those back side faces were not selected.

- Michael

Very nice !

Thanks.