Hi wayne,
re:
> Question...
>
> Why doesn't a boolean difference between a bolt and a nut work on a thread form on the nut?
It's because of areas like this where the parts just barely skim across each other's surface area:
In order to do a successful boolean, there has to be a set of intersection curves generated which form closed and non-self-intersecting loops to divide the objects up into pieces.
It is difficult in general to get a clean well ordered intersection when 2 objects just barely skim or graze across their surface areas like that.
You can use Construct > Curve > Isect to generate intersection curves and see some of the problematic spots.
Usually it is best to avoid doing booleans with just barely grazing surfaces like this, it is better for pieces to push through each other by some amount rather than just barely graze, although it usually is ok if the 2 surfaces are very exactly coincident like with 2 planes. A sweep is only accurate to the fitting tolerance so a sweep coincident with something else will not usually work very well for booleans.
- Michael
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