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I'm trying to make characters that kind of resemble tennis balls with happy faces. Basic Boolean methods end up removing part of the objects.

I want to have 2 objects overlap and Blender creates new vertices on the faces where the edges pass through. I don’t want anything removed by the Boolean process. I only want the vertices created so I can modify what I need afterwards on my own.

Take a sphere.
Put a cylinder through it.
Then create vertices on the sphere faces where the cylinder passes through.
This marks where an eye will be. Repeat for the rest of the character.

Ball face

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    $\begingroup$ If you are speaking about faces ... you can use Knife Project, but isn't it more efficient to use image texture? $\endgroup$
    – vklidu
    Aug 12, 2021 at 13:17
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    $\begingroup$ You could use the knife project tool with a circle as the cutting object for something like that. Quick tutorial here. $\endgroup$
    – John Eason
    Aug 12, 2021 at 13:17
  • $\begingroup$ I’m using cone shapes so I can have perfect control over the symmetry, shapes, angle, size, and location of the objects. Knife Project requires an extreme level of skill to consistently align things perfectly. I make a cone and stick the cone through the ball and the top of the cone is centered in the exact center of the ball. I can type in the exact coordinates I want and rotate like a spotlight, so I never have to eyeball anything. $\endgroup$
    – senseigo
    Aug 13, 2021 at 1:00

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Sorry I didn't get the goal all of this ... your OP is about Cylinder, comment about a Cone ... probably I can't imagine the final product ....

Knife Project

  • Create your shape (smile) with origin in center of ball, vertices move above ball surface
  • With smile object selected you can rotate around a ball as you like

enter image description here

  • To get aligned view for projection - go to View > Align View > Align View to Active
    in this case Top Shift+7

enter image description here

  • with Shift select Ball, switch to edit and search for Knife Project operator

Result - perfectly aligned cut "smile" according to your object orientation by single click.

enter image description here

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