I have a super simple flat piece of geometry here which I have cut out of with boolean modifiers.
The issue I am encountering is that along many of the cutout edges, there are lots of floating faces.
Image 1 and
Image 2 depict show this issue. I have used the rainbow matcap just so it's easier to see the issue.
Image 3 is what the correct bevel should look like.
I have done some troubleshooting. My modifier stack with this issue was comprised of a Boolean operation with a bevel modifier attached to it. I applied the boolean operation and took a look at the topology of the object.
Image 4 depicts the geometry of the issue. If I auto merge the outermost two edges, the issue gets solved, making the corner look like
Image 3. However, this can't possibly be an acceptable thing.
How do I solve it so that the bevel works without creating these extra faces?
I have made the blend file available here: https://files.catbox.moe/jvcwlx.blend
In the file are two attempts by me to resolve the issue.
obj #1 is the one that you can see in the screenshots in this post
obj #2 is a fresh attempt to recreate the issue. Note that in this obj, I havent applied the scale. To get a decent bevel, you will need to apply the scale. I have purposely left it unapplied because that might possibly be a factor causing the issue.
I have tested the issue in both 2.9x and 3.0 and it exists in both.
Let me know if you need anything else.