Hi jetblast - it tends to be difficult for the booleans to handle a lot of extremely thin compressed needle-like matchups between pieces, which you have quite a bit of in this case here. Things like this very narrow collapsing area here for example:
That's some just fundamentally difficult stuff for booleans to process, some of those very thin areas will be considered to be overlapping and others will be considered to be distinct and that tends to make it hard to get a clean set of closed intersection curves out of the intersection calculation.
It's better for pieces to be either be more exactly matching up, or to have more distinct clearance between them rather than this type of thing with things coming close to one another but being separated by some very thin amount like that.
What is it that you're trying to get by unioning these together, you may need to use a different strategy and keep them as separate objects rather than trying to combine them, either that or do the opposite type of thing and start with a larger object and then divide up the large object into slices rather than trying to combine very slightly different slices together.
I think the booleans already got confused on some of your prior unions, the larger piece seems to have some messed up trimming boundaries in it, in an area where it looks like some shaded surface is kind of leaking outside the object.
- Michael
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