Some times when using a Boolean modifier, it will return the error "Cannot Execute Boolean Operation".
This will often happen with multiple Boolean modifiers.
Here is an example file.
What causes this? How can I work around this?
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$\begingroup$ @zeffii I have updated the question with an example .blend $\endgroup$– gandalf3Commented Aug 18, 2013 at 22:00
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$\begingroup$ @gandalf3 it's hard to know what your intention was, but currently you are performing a boolean using cube.002 twice, shouldn't the 1st or 3rd boolean use cube.001? $\endgroup$– Ray MairlotCommented Aug 18, 2013 at 22:43
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$\begingroup$ stacking booleans is going to get messy when you can't visually see the result of previous booleans. The whole modifier stack is this additive beast, which you are losing control of. $\endgroup$– zeffiiCommented Aug 18, 2013 at 22:46
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$\begingroup$ Related: blender.stackexchange.com/q/5140/599 $\endgroup$– gandalf3Commented Mar 7, 2014 at 7:11
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$\begingroup$ I'm having a similar problem. i'm trying to add a boolean modifier, to cut a hole in a shape by using a cylinder. I get: "uncontained hole loop does not share vertices with any face loop" "CSG failed, exception Failed to merge holes" any idea? $\endgroup$– juFoCommented Sep 26, 2014 at 8:52
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3 Answers
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My best guess would be the clue that the console window provides upon opening the file:
"...intersecting group is not in or out".
Because you are trying to union a mesh that has already been 'unioned' (cube.002 is the union object on boolean modifiers 1 and 3) there are no intersections that the boolean can detect, the faces of the object you are trying to union (cube.002) are directly on top of faces that are already there (the cube.002 previously 'unioned').
If there are no intersecting faces then there is nothing to join. The faces of the mesh to be 'unioned' are neither inside the current mesh not outside of it, they are directly on top of it.
I openly admit this is just my theory based on the error message so I could be wrong. I would presume, based on the objects included in the blend file that this is a simple mistake of using 'cube.002' twice as 'cube.001' isn't used in any of the booleans.
answered Aug 18, 2013 at 22:53
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$\begingroup$ That was it, thanks. (now how did that happen... :P) I have had this happen to me before, but it is always possible it is just me screwing up there too. I'll look around and see if I can find some of those old files. $\endgroup$– gandalf3Commented Aug 18, 2013 at 23:06
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Then the face or object that's being applied with a booean doesn't have enough vertices on it. subdivide the face or use the knife tool to create many edges on that face.... C4our your welcome 
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It may be, there are missing some faces, from your "Cutter" object. Turn on the face selection mode (in edit mode -> ctrl+tab) and check for missing faces.
