Boolean fails for non-manifold

tim_elston

https://cad.onshape.com/documents/abee862d6bd51cefcff28e3a/w/104459627f81061d3c1e6ad1/e/820a39916cd296516a97f53d

Sketch 7 and 8 are lofted and thickened to form a body - part 7. 

Fill 4, thicken 7 and Boolean 6 seal one end of the body - still part 7. 

Fill 5 and thicken 8 seal the other end - part 8.

Boolean parts 7 and 8 fails for non-manifold!  Why?  How to resolve?

S1mon

The end cap (part 8) that you created has faces on the edges which are not quite coincident with the inside of the lofted tube (part 7). When surfaces wobble in and out of being coincident like that, it's likely that you'll get some point or line contacts, which the Parasolid kernel can't deal with.

It would be much easier to loft a solid and then use shell to get the wall thickness that you want. That would turn 7 features into 2, and be much more robust.

CFraser100

Have you checked they share a common area or are touching?

S1mon

The end cap (part 8) that you created has faces on the edges which are not quite coincident with the inside of the lofted tube (part 7). When surfaces wobble in and out of being coincident like that, it's likely that you'll get some point or line contacts, which the Parasolid kernel can't deal with.

It would be much easier to loft a solid and then use shell to get the wall thickness that you want. That would turn 7 features into 2, and be much more robust.

tim_elston

Thank you! Another new approach to design approaches.