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Very often I'll get erratic results with a Boolean operation on two objects with overlapping faces. The most usual result is missing faces in the combined object, or else internal faces are left after a Union, for example.

Why is this? Is there anything I can do to avoid it?

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    $\begingroup$ for information on errors with boolean operations read: Boolean Modifier not working. Pay special attention to the section that describes Overlapping geometry between objects $\endgroup$ – cegaton Feb 19 at 21:55

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