A way of bevelling the boolean seams...

[Dimitri]

Sure, it is a method that can not be applied in every case… but in some cases works well, so the idea should be shared. : - )

You unify two objects… then you select a single edge of the ‘seam’ loop between the two unified objects and go to ML add ons’ ‘select’ options… there you click ‘straightest path’, so that you may be able to select in one move the loop. When the loop is selected you go to ‘tubes by loop paths’ of ML tools (the command is in the right click menu)… you produce a tube –of whatever thickness you want- and, then, you unify the object with the tube also, using booleans again. Now you have a single object. You select the non seam constituting loops on the tube… you delete them… you make a ‘cleaning up’ (in the 'right click' menu of the body mode)… and there, you have a nicely formed bevel on the seam between the initial two objects.

The whole procedure is quite easy, as is evident from the three-step image below. I do put a render of a more complex object built by an arrangement of such initial pieces, so that may I show how good results there may be acquired by using this way of bevelling (the rendering has been done in Blender with the use of its new npr renderer Freestyle – you can do many things with it, given that you be familiar with its working ways).