Is an approach like this one equivalent to what you describe?
- Using a Rigid Body simulation with collision, pour a bunch of balls into a box:
Choosing a stable frame at the end of the simulation..
- CtrlA Apply visual transforms to the balls, and in the Tool Region > Physics, remove them from the simulation.
- With the pivot set to 'Individual Origins', scale the balls up to your interference margin, apply the scales, and reintroduce the inside surface of the box, flipped, sealed, and scaled.
Using the Bool Tools shipped add-on..
- Make a union of the balls..
- and subtract them from the box
. The thickness depends on the scaling of the spheres before union.plus clean-ups, etc.