System Information
Operating system: macOS Monterey (ARM64)
Graphics card: Apple Silicon M1
Blender Version
Broken: 3.2.0 Alpha & others
Worked: *2.83.X*? (reported in comment)
Short description of error
Booleans can often be very touchy and may require positioning them just right for them to do operations properly. It seems that it really depends on where the vertices line up. I've been cutting window slots out of ridged galvanized steel plates using boolean cubes and it's worked for every other object. However, this one particular piece in my scene has been causing endless trouble for me despite being the exact same procedure. Seems as though I need to put my boolean objects in the EXACT RIGHT place for them to work right. I found that adding a ludicrous number of subdivisions w/ the subsurface modifier can somewhat help, but it greatly depends on whether or not I position my cubes in the right spot. It is preventing me from placing my windows where they need to go on my scale accurate historic building recreation. I don't know why this object is being so temperamental but it is blocking me from making any progress on this side of the building and I'm afraid I'll keep running into the problem later on.
I may post additional demo files that showcase more boolean issues as I frequently run into problems of faces not being filled properly, crappy vertex extrusions, objects being weirdly combined instead of differenced, and many more annoyances. I hope booleans can get a lot more love from the developers so that they work as intended.
Exact steps for others to reproduce the error
I'm not entirely sure how to reproduce an issue like this. It mostly plagues more detailed models but can happen anywhere and depends on object positions, alignment, topology, and so on. Attached is a problematic file.
Attached file information
F12870489 There are several issues present. For one thing, the boolean modifier is struggling to cut a simple rectangle out of a plane. It is adding geometry to certain parts, cutting out geometry that shouldn't be cut out, and is not accurate at all. I've noticed that using the "fast" option usually yields better results than using the "exact" option. However, in the case of this object, it actually breaks it EVEN MORE! Try selecting the "cutoutGalvanizedSteel" (planar object) and setting the booleans to "fast" to see a new problem emerge. Adding a solidify modifier to the very top of the stack will fix the issue. However, booleans should work on planes, too.
F12871474 Many different problems. Boolean objects are displayed as wireframes. If you see a boolean as having geometry, it's because it is being added by the Boolean modifier. The boolean modifier likes to add the boolean's geometry to the source mesh sometimes, even when it is set to difference or intersection. In issue 2, there is a mesh problem in the boolean. If you enter edit mode, you can see that the problematic vertices are selected. They crash the boolean operation altogether. Merging these vertices will solve the issue, but for more complex boolean objects, this may not always be an option.


