On 2025-09-01 13:12 (-4), Bald Eagle wrote:
> kurtz le pirate <kur### [at] freefr> wrote:
> 
>> The attached image illustrates the issue well. Both objects are defined
>> in the same way, but one is a union{} (magenta) and the other is a
>> merge{} (cyan).
>>
>> It's a very very simple object: two boxes and four cylinders.
> 
> And that's the root of the problem:  it's TOO simple.
> 
> Remove the overlap of the two boxes by defining one central box, and adding FOUR
> "leaves" or "wings" filling in the edges between the cylinder "corners".
> 
> Then I think it should work . . .
> 
> However, you may need to convert your corners from full cylinders to "pie
> slices" by CSG - either home-rolled, or using Lohmueller's macro, which I
> believe is in the drop-down insert menu as "segment of a cylinder"

I'm not sure this will solve the problem; it may just result in a
different set of coincident surfaces.

If you want to see what I went through to build this shape without
coincident surfaces, take a look at macro RE__box_axis() in this file:
  https://github.com/CousinRicky/POV-RoundEdge/blob/main/roundedge.inc

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