This displays fine, until I try a top-level render (either in code or from
the menu...)

Then I get:
ERROR: CGAL error in CGALUtils::applyBinaryOperator difference: CGAL ERROR:
assertion violation! Expr: G.mark(v1,0)==G.mark(v2,0)&&
G.mark(v1,1)==G.mark(v2,1) File:
/mxe/usr/x86_64-w64-mingw32.static.posix/include/CGAL/Nef_S2/SM_overlayer.h
Line: 303

Thoughts?

[code]

/////////////////////////////////////////// MAIN CODE
////////////////////////////////

include <utilities/utils.scad>

module insertHole(depth)  {
//scale([25.4,25.4,25.4]) {
/#10 insert/ insH=6;insR =3.75;
coneR1=insR-.5;coneR2=insR+.5;rad=2.25;
insert(depth,insH,coneR1,coneR2,rad);
//}
}

//module roundTube(height,radius,wallTh,x,y,z)
//NAME
////////////////////////// DIMENSIONS  //////////////////////////
mm=25.4;
latchW=46;
latchH=20;
latchD=6;
side=5;
w=80;
oW=150;
l=200;
slotW=64;
slotH=8.5;
slotMin=56;
gapY=18; //28 from end of slot
latchZ=28; //to top of slot...
//inset=46;
tabD=11;
rnd=3;
bagR=8;
pomR=25;
rackH=40;
fl=5;
scR=(.294mm)/2;
sR=.078mm;
tabW=24;
footR=tabW/2;

rightC=(2.5*mm) -.078;  //screw radius  //w/2-((w-slotW)/4);
leftC=-rightC;

module slot()  {
translate([0,l/2+bagR+bagR,0])
rotate([90,0,0])
linear_extrude(height = l+20, center= true)

polygon([[-slotW/2,0],[slotW/2,0],[slotMin/2,slotH],[-slotMin/2,slotH]]);
}

module infill(length)  {
render()
rotate([-90,0,0])
rotate([0,90,0])
pillarFillet(bagR,length,rnd);
}

module latchHole() {
roundVol(-latchW/2,latchW/2,-50,50,slotH,latchZ,rnd);
roundVol(-latchW/2,latchW/2,-tabD+latchD,10,slotH,50,rnd);
translate([-latchW/2,-side-side,latchZ+ side])
rotate([0,90,0]) render()
pillarFillet(side,latchW,rnd);
}
module arch() {
translate([w/2-pomR,0,rackH-pomR])
rotate([90,0,0])
invQuarterRoundCyl(pomR,tabD+rnd,rnd);
}
module leftarch() {
mirror([1,0,0]) arch();
}

module pommel()  {
difference() {
union() {
translate([-w/2,bagR,bagR+slotH]) infill(w);
roundVol(-w/2,w/2,-tabD-rnd,0,-fl-rnd,rackH,rnd);
volume(-slotW/2,slotW/2,-10,bagR,-10,slotH);
}
volume(-100,100,-100,10,-100,-fl);
volume(-100,100,-100,-tabD,-100,100);
latchHole();
arch();
leftarch();
//slot();
}
}
module plusIns(yVal)  {
translate([oW/2-footR,yVal,-fl-10+2])
insertHole(10);
}
module minusIns(yVal)  {
mirror([1,0,0]) plusIns(yVal);
}
module inserts(yVal) {minusIns(yVal);plusIns(yVal); }
module rack()  { //render()
//legs
roundMintVol(-oW/2,oW/2,0,tabW,-fl-rnd,2,footR,rnd);

roundMintVol(-oW/2,oW/2,(l/2)-(tabW/2),(l/2)+(tabW/2),-fl-rnd,2,footR,rnd);
roundMintVol(-oW/2,oW/2,l-tabW,l,-fl-rnd,2,footR,rnd);
difference()  {
union() {
//main body
roundMintVol(-w/2,w/2,-20,l,-fl-rnd,8.5,footR,rnd*2);

    }  
     
    //volume(-100,100,-10,200,-20,-5);
    volume(-100,100,-25,-latchD,-20,20);
    
    
    //mintVol(-slotMin/2,slotMin/2,tabW,80,-10,10,10);
    volume(-slotMin/2,slotMin/2,0,l,-10,10);
    
    
}

}

module envelope() {

 pommel(); 
 rack();     

}

module unit()  {
difference()  {
envelope();
volume(-100,100,-10,250,-100,-fl);
inserts(footR);inserts(l-footR);inserts(l/2);
slot();
}
}

//scale([25.4,25.4,25.4]) {  //to mm
$fn = 64;  //render()
unit();
//pommel();
//plusInsert(0);
//translate([100,0,-slotH]) rotate([90,0,180])
import("mtx_mount_6.stl");
//translate([0,.5,.75]) unit();
//}
//$fn = 16; render() unit();
//}

//////////////////////////////////////////UTILITIES.SCAD///////////////////////////////
mm=25.4;
$fn=16;

module mintBox(length,width,height,rad) {
hull()  {
translate([rad,rad,0]) cylinder(r=rad,h=height);
translate([length-rad,rad,0]) cylinder(r=rad,h=height);
translate([rad,width-rad,0]) cylinder(r=rad,h=height);
translate([length-rad,width-rad,0]) cylinder(r=rad,h=height);
}
}
module donut(radius,thickness,x,y,z)  {
total = thickness+radius; //larger than either!
translate([x,y,z+thickness/2])
rotate_extrude()
intersection()  {
translate([radius-thickness/2,0,0])
circle(r = thickness/2);
translate([0,-total]) square(total2);
}
}
module mouth(rad,h) {
intersection()  {
donut(rad+h,h2,0,0,-h);
cylinder(h=5,r=rad);
}
}
module quartermouth(rad,h)  {
intersection()  {
mouth(rad,h);
volume(0,rad,0,rad,0,h);
}
}
module quarterCyl(rad,h) {
intersection() {
cylinder(h=h,r=rad);
volume(0,rad,0,rad,0,l);
}

}
module fillet(rad,h)  {
difference() {
volume(0,rad,0,rad,0,h);
cylinder(h=h,r=rad);
}
}
module mintFillet(rad,h,w,d)  {
// width and depth are exterior.  Interior is minus height...
//corners
translate([w-rad,d-rad,0]) quartermouth(rad,h);
translate([rad,d-rad,0]) rotate([0,0,90]) quartermouth(rad,h);
translate([w-rad,rad,0]) rotate([0,0,-90]) quartermouth(rad,h);
translate([rad,rad,0]) rotate([0,0,180]) quartermouth(rad,h);
//edges
translate([0,d-rad,0]) rotate([90,0,0]) quarterCyl(h,d-rad-rad);
translate([w,d-rad,0]) rotate([90,-90,0]) quarterCyl(h,d-rad-rad);
translate([rad,0,0]) rotate([90,0,90]) quarterCyl(h,w-rad-rad);
translate([w-rad,d,0]) rotate([90,0,-90]) quarterCyl(h,w-rad-rad);
}
module roundTube(height,radius,wallTh,x,y,z)  {
donut(radius,wallTh,x,y,z);
donut(radius,wallTh,x,y,z+height-wallTh);
difference()  {
translate([x,y,wallTh/2+z]) cylinder(r=radius,h=height-wallTh);
translate([x,y,wallTh/2+z])
cylinder(r=radius-wallTh,h=height-wallTh);
}
}
module pillar(rad,height,rnd)  {
difference() {
cylinder(r=rad+rnd,h=height);
roundTube(height,rad+rnd+rnd,rnd*2,0,0,0);
}
}
module quarterPillar(rad,height,rnd)  {
intersection() {
volume(0,rad,0,rad,0,height);
pillar(rad,height,rnd);
}
}

module pillarFillet(rad,height,rnd) {
difference() {
volume(0,rad+rnd,0,rad+rnd,0,height);
pillar(rad,height,rnd);
}
}
module roundedCube(x,y,z,rad)  {
hull()  {
translate([rad,rad,rad]) sphere(rad);
translate([x-rad,rad,rad]) sphere(rad);
translate([x-rad,y-rad,rad]) sphere(rad);
translate([rad,y-rad,rad]) sphere(rad);
translate([rad,rad,z-rad]) sphere(rad);
translate([x-rad,rad,z-rad]) sphere(rad);
translate([x-rad,y-rad,z-rad]) sphere(rad);
translate([rad,y-rad,z-rad]) sphere(rad);
}
}

module pill(radius,thickness,x,y,z)  {
hull() { donut(radius,thickness,x,y,z); }
}
module quarterPill(radius,thickness)  {
intersection() {
vol(0,radius,0,radius,0,thickness);
pill(radius,thickness,0,0,0);
}
}

module mintVol(xmin,xmax,ymin,ymax,zmin,zmax,rad) {
hull()  {
translate([xmin+rad,ymin+rad,zmin]) cylinder(r=rad,h=zmax-zmin);
translate([xmax-rad,ymax-rad,zmin]) cylinder(r=rad,h=zmax-zmin);
translate([xmin+rad,ymax-rad,zmin]) cylinder(r=rad,h=zmax-zmin);
translate([xmax-rad,ymin+rad,zmin]) cylinder(r=rad,h=zmax-zmin);
}

}
module roundMintVol(xmin,xmax,ymin,ymax,zmin,zmax,rmax,rmin) {
hull()  {
donut(rmax,rmin,xmin+rmax,ymin+rmax,zmin);
donut(rmax,rmin,xmax-rmax,ymax-rmax,zmin);
donut(rmax,rmin,xmin+rmax,ymax-rmax,zmin);
donut(rmax,rmin,xmax-rmax,ymin+rmax,zmin);
donut(rmax,rmin,xmin+rmax,ymin+rmax,zmax-rmin);
donut(rmax,rmin,xmax-rmax,ymax-rmax,zmax-rmin);
donut(rmax,rmin,xmin+rmax,ymax-rmax,zmax-rmin);
donut(rmax,rmin,xmax-rmax,ymin+rmax,zmax-rmin);
}
}
module roundVol(xmin,xmax,ymin,ymax,zmin,zmax,rad) {
hull()  {
translate([xmin+rad,ymin+rad,zmin+rad]) sphere(r=rad);
translate([xmax-rad,ymax-rad,zmin+rad]) sphere(r=rad);
translate([xmin+rad,ymax-rad,zmin+rad]) sphere(r=rad);
translate([xmax-rad,ymin+rad,zmin+rad]) sphere(r=rad);
translate([xmin+rad,ymin+rad,zmax-rad]) sphere(r=rad);
translate([xmax-rad,ymax-rad,zmax-rad]) sphere(r=rad);
translate([xmin+rad,ymax-rad,zmax-rad]) sphere(r=rad);
translate([xmax-rad,ymin+rad,zmax-rad]) sphere(r=rad);
}
}
module volume(x,xTop,y,yTop,z,zTop) {
box(x,xTop-x,y,yTop-y,z,zTop-z);
}

module box(a,x,b,y,c,z) {
translate([a,b,c]) cube([x,y,z]);
}

module roundCyl(rad,height,rnd) {
hull() {
pill(rad,rnd2,0,0,0);
pill(rad,rnd2,0,0,height-rnd-rnd);
}
}
module quarterRoundCyl(rad,height,rnd){
intersection() {
volume(0,rad,0,rad,0,height);
roundCyl(rad,height,rnd);
}
}
module invQuarterRoundCyl(rad,height,rnd){
difference() {
volume(0,rad,0,rad,0,height);
roundCyl(rad,height,rnd);
}
}

module ring(iD,oD,height,rnd)  {
diam=(oD-iD)/2;
difference()  {
translate([0,0,rnd/2]) cylinder(r=oD,h=height);
translate([0,0,rnd/2]) cylinder(r1=largeR,r2=smallR,h=height);
}
donut(diam,rnd,0,0,0);
donut(diam,rnd,0,0,height);
}

module teensy()  {
x=35.56;y=17.78;z=1.57;//circuit board
usbY=8.06;usbI=(y-usbY)/2;//usb jack
scale([1/mm,1/mm,1/mm]) translate([-x/2,-y/2,-z/2]) color([.3,.5,.3])  {
cube([x,y,z]);
volume(-.06,5,usbI,usbI+usbY,z,z+2.5);
}
}
module breadboard()  {
cube([3.22,2.02,.08]);
}

module flatheadHole(length,shaftRad,headRad,headTh,recess) {
translate([0,0,-length-.001]) cylinder(r=shaftRad,h=length+.002);
//for flathead
translate([0,0,.001-headTh]) cylinder(r1=shaftRad,r2=headRad,h=headTh);
translate([0,0,0]) cylinder(r=headRad,h=recess);
}
module insert(scrLength,insH,coneR1,coneR2,scr) {
union() {
translate([0,0,-.01]) cylinder(r=scr,h=scrLength+.02);
translate([0,0,scrLength])
// cylinder($fn=6,r=hexR,h=hexLength);
cylinder(d1=coneR1,d2=coneR2,h=insH);
}
}

module insertHole(xpos,ypos,zpos)  {
top=.25;bottom=.21;height=.312;sR=.084;
translate([xpos,ypos,zpos-height]) cylinder(d1=bottom,d2=top,h=height);
translate([xpos,ypos,-1]) cylinder(r=sR,h=zpos+1);
}
module sm58() color([.3,0,.7])  {
rimD=2.01;  //diameter
ballD=1.925;
rimH=.18;
handleD=1.33;  //diameter
handleH=.24;
collarH=.21;
collarD=1.525;
rimToTube=1.145;//bottom of tube to center of rim
intersection()  {
sphere(d=ballD);
volume(-2,2,-2,2,-rimToTube,2);
}
translate([0,0,-rimH/2]) cylinder(d=rimD,h=rimH);
translate([0,0,-rimToTube-.75]) cylinder(d=handleD,h=handleH+.75);
//handle
translate([0,0,-rimToTube+handleH])
cylinder(d1=handleD,d2=collarD,h=collarH);//collar
translate([0,0,-rimToTube+handleH+collarH])
cylinder(d=collarD,h=.5);//collar smoother
}

//tests
module mintFilletTest()  {
x=50;y=18;rad=2;
mintFillet(rad,1.6,x,y);
mintVol(0,x,0,y,-3,0,rad);
}
module mouthTest()  {
quartermouth(4,1);
}
module filletTest(){
fillet(1,4);
}
module pillarTest() {
pillarFillet(16,100,3);
}
//render() quarterPillar(5,10,3);
//render() pillarTest();
//filletTest();
//mouthTest();

[/code]

--
Sent from: http://forum.openscad.org/

If it helps, the same main file using this (slightly modified) version of
utlities.scad fails silently without giving any error at all....

utils.scad http://forum.openscad.org/file/t2632/utils.scad

--
Sent from: http://forum.openscad.org/

Did some more sleuthing....

I found it will render module pommel() or module rack(), BUT NOT BOTH!

I tried encosing them in a union, in case that mattered, but it doesn't
help....

I tried moving pommel() inside rack(), but that doesn't help either.

I tried rendering both modules before unioning them, that didn't help.

I should mention I'm using 2019.05 under win10 64.

Frustrating that it doesn't indicate what in my code caused the error.

Here's the latest trace:
Loaded design 'C:/Users/emoon/Documents/Drawings/OPENSCAD/topeakRack.scad'.
Compiling design (CSG Tree generation)...
Compiling design (CSG Products generation)...
ERROR: CGAL error in CGALUtils::applyBinaryOperator union: CGAL ERROR:
assertion violation! Expr: itl != it->second.end() File:
/mxe/usr/x86_64-w64-mingw32.static.posix/include/CGAL/Nef_3/SNC_external_structure.h
Line: 1152
Geometries in cache: 146
Geometry cache size in bytes: 33118200
CGAL Polyhedrons in cache: 8
CGAL cache size in bytes: 85562872
Compiling design (CSG Products normalization)...
Normalized CSG tree has 1 elements
Compile and preview finished.
Total rendering time: 0 hours, 1 minutes, 1 seconds

--
Sent from: http://forum.openscad.org/

Thanks for the tip.  I have tried to track it down from there, and got to
this point:

This works:

        rack(); 
        //translate([-w/2,bagR,bagR+slotH]) 
        infill(w);

but this doesn't:

        rack(); 
        translate([-w/2,bagR,bagR+slotH])  infill(w);

How can just moving one of the (all rendering individually without
complaint) parts create a non-manifold???

infill is fine by itself, it's fine with rack, but if I move it it's not?
What do I do??

--
Sent from: http://forum.openscad.org/