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So I'm trying to make a smooth spherical cut in my object, I'm using the same object (icosphere) to cut both my meshes and it's worked fine on the right (hammer spike) and made new faces where it's cut, but its not making new faces on the left mesh (hammer head).

If it matters I had used a different object (UV sphere) earlier on the same object but removed that side made with that boolean and duplicated the front, mirrored it, and joined the vertices to make edges and faces. Then I separated the left and right meshes into new groups as you can see in the outliner.

I removed duplicate vertices and the face normals are correct, I've also tried a solidify modifier like some other related problems prescribe but it just made it more wacky.

how do I make the boolean tool make the new faces like it has before?enter image description here

enter image description here

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The problems I have with booleans usually relate to two meshes having one or more vertices in the same place. You might be able to fix this by scaling one of the objects slightly, but this obviously will change its size. You might be able to manually move the offending vertices out of each others' way.

Another possibility is you created an object in an older version of Blender, and have now opened it in a newer version of Blender. The data structures are not the same, and booleans will give unexpected results.

Another thing you can try is to run the 3d printing checks, and fix any problems that crop up before applying your booleans.

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