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I created a cube out with just Curve paths and filled it as shown at the screenshot. But this mode creates intersecting parts (Screenshot 3-4) Is there a way to do this without intersecting parts?

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Settings

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Intersections

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  • $\begingroup$ Don't forget to upvote if any of the answers helped you ;-) $\endgroup$ – Samoth Apr 12 '16 at 20:21
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To make a perfectly "flat" cube here's another method:

  1. Duplicate the Default Cube (Shift D), name it "inner".
  2. With your inner Cube selected switch to Edit Mode (Tab).
  3. Inset your Faces:
    • With every Vertex selected (A) hit I for Inset and then hit I again to toggle Individual On.
    • Type 0.25 or how broad you want your outer Grid-Frame to be. Confirm with LMB or Enter.
  4. Invert your selection to select all corner Vertices. Maybe there's a bug, but it will only work properly after you perform and undo the inverse again. So press Selection > Inverse Ctrl I, Undo Ctrl Z and Selection > Inverse again Ctrl I.
  5. Scale your corner Vertices accordingly to your previous Inset width. You need to substract the Inset width from 1.0, so in this example Scale (S) by , 7 5 (1.0 - 0.25 = 0.75). The result will look a bit off while your Vertices are still selected, but once you deselect them, everything looks perfect.
  6. Now hide the inner Cube after leaving Edit mode (H) so that it won't overlap with the next steps result.
  7. Add a Boolean modifier in the Modifiers Properties Tab to your not yet changed Default Cube with a Different Operation and the inner Cube as Object et voilà:

Flat Cube Frame

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  • $\begingroup$ When you want to have a clean edge structure on your result, you can first do a Triangulate Faces with Ctrl+T and then perform Tris to Quads with Alt+J and select a large Max Shape Angle there (F6). $\endgroup$ – Samoth Mar 4 '16 at 11:08
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Well,This expected from what you did.There is no way to solve this.

Instead you can use the Wireframe modifier to generate a similar result.

Wireframe

You can also flatten the face to get a more neat result:

Neat

Flatting can be done using the keys S + Axis + 0 after selecting the right faces.

Flatting

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  • $\begingroup$ How can this flattening be done? $\endgroup$ – Samoth Mar 3 '16 at 22:16
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    $\begingroup$ @Samoth I Edited the answer $\endgroup$ – Omar Emara Mar 4 '16 at 8:31
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  1. Duplicate the default Cube, name itself Grid and the other one inner.
  2. Select the inner Cube and in Edit Mode select every Vertex (A), then use an Edge Bevel (Ctrl B) of 0.25, then hide it.
  3. Select the Grid Cube and add a Boolean Modifier with the inner Cube as Object in Difference mode. (This will cut out the inner part)

Example Result

You could of course play with the Bevel of your inner cube before to get your grid nicer looking. You could use more Segments or change the Profile from 0.5 which is "flat" to a smaller number like 0.25 to get a more rounded grid-frame. Its settings are available in the panel in the Toolbar once you confirm the Bevel before doing any other operation or by hitting F6. Unfortunately there's a restriction to the Bevel Operation that you can't set the Profile to something lower than 0.15. So you won't be able to produce a "flat structure* with it.

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