I have an object made in blender which needs to prepared for 3D printing. It is relatively complex object (114k verts, 228k faces, 228k tris) which contains three separate meshes.
I separated the object by loose parts, checked for non-manifold geometry, converted ngons to triangles, and am now attempting to perform boolean Union on them. Blender shows
Cannot execute boolean operation, and CMD displays
CSG failed, exception degenerate edge.
What's going on here?
Modifier seems to work without an error if and only if objects don't intersect. That is a problem, since all my objects intertwine. Object parts were designed to intersect. For instance, a person representing a sword. Sword is a bit thicker than the hole in the person's hand to ensure structural integrity of a printed model.