Unable to Boolean Union two intersecting parts

norman_sloane

Greetings, everyone! 

This is my first project on OnShape, and one of my first CAD projects in general, and it has been going decently well so far. I joined one extruded shape to another, however when I tried to do so with the second extruded shape, it will join them, but I can still see the edges and it exists as a separate shape when performing actions such as chamfering? It seems to join any other shape except this particular one. I looked around a bit on the forums, and I've made sure they're intersecting. Any advice would be greatly appreciated! 

https://cad.onshape.com/documents/44e1cffda40bbd7b81545355/w/c70e61c1b402251b6cbd133a/e/d60b20a11d6d481519df011c?renderMode=0&uiState=64e293707fc1ab2ae3cc11d3

Alex_Kempen

You can select additional parts to boolean things together (use the parts list in the bottom left to determine what unique parts you actually have). It looks like there are issues from where you haven't properly constrained geometry together, however, leaving some microscopic misalignment in your parts.

S1mon

First off, you could probably create this shape with a few features instead of so many. There are a zillion different ways to make something like this, but using a lot of move face commands is probably not the most robust and easy to debug method.

This is missing some smaller details, but here's a pass at the main shape in 7 features. I deleted some of the random broken stuff from the import and I transformed the STL to be more usefully aligned with the default planes/origin.

https://cad.onshape.com/documents/1ab96201fbe08671c0f3491d/w/c5fa36123ddaf572c8397753/e/e80303b1dad84a27acd42d36

norman_sloane

I believe I attempted to Boolean the parts together as well, unfortunately, it did not have much difference. It is likely a misalignment in the design of the extruded objects, since I was working with a fairly fractured STL. Perhaps I should go back and learn some more of the basics of card, software, and then attempt to re-design it from scratch to make sure that things are aligned and properly sized?

norman_sloane

Oh wow, that’s fantastic! I will study this one for future designs, and likely take a look at some online tutorials to start from scratch. Prior to this, I had only done some basic stuff with TinkerCAD. S1mon said:

First off, you could probably create this shape with a few features instead of so many. There are a zillion different ways to make something like this, but using a lot of move face commands is probably not the most robust and easy to debug method.

This is missing some smaller details, but here's a pass at the main shape in 7 features. I deleted some of the random broken stuff from the import and I transformed the STL to be more usefully aligned with the default planes/origin.

https://cad.onshape.com/documents/1ab96201fbe08671c0f3491d/w/c5fa36123ddaf572c8397753/e/e80303b1dad84a27acd42d36