Boolean Union

[Anonymous]

I am trying to mesh two dental arches together for 3D Printing. I have used the attract tool to get the lower arch close to the upper arch then try to boolean union the two meshes together, but I get a bunch of errors. I have included screen shots below for your reference. Is there a better way to mesh these two arches together? 

  

[Anonymous]

Are you sure that you need to merge both meshes to one surface? There are 3D printing slicers out there handling intersecting surfaces combined to one file just fine. Check if your slicer handles such files. If so you just need to activate both objects and run Combine instead of BooleanUnion.

BooleanUnion fails if there are too many intersections too close to each other. You might play with boolean settings  or Combine the objects and weld them using EDIT/MakeSolid at a high SolidAccuracy and MeshDensity.