funky faces 3ds
When you use booleans on complex objects, it's very important to "match"
the density of both objects involved. If you don't, and the boolean
operation creates long, skinny triangles, you're going to get those kinds
of rendering artifacts. Go back to your original objects and tessellate
each of them one time and try again. That ought to do it for you. If
you're getting just a _little_ shading discontinuities, you can always put
a subtle stippled map on the plastic to mitigate that (but you shouldn't
need to resort to this if you get the densities of the meshes right before
the boolean op).
– G
PS: If you need any more help with this, I'll be gone as of later tonight
for awhile. Contact Jack Powell or one of the other genius' here for help.
Thanks.