Blender’s Boolean modifier is not suitable for cutting with complex geometry. You should always try to stick with the primitive shapes. But even if you do that, it can result in nasty artifacts. That’s why it’s important to take measures before applying the modifier. Here’s an example on how to do that on the Frustrum pillar.
For starters, here we have the pillar, and the cylinder which we will be using to cut the hole in the mesh.
If we were to apply the modifier now, all faces of the cone touching the cylinder would be affected by the modifier. This is an issue, because the faces are way bigger than the cylinder, and it leaves much room for artifacts.
What we need to do it make the zone that the Boolean modifier can affect as small as possible. By using the knife tool, we can add extra edges to isolate the area around the cylinder.
If we put the cylinder back again, we can see that it only touches the highlighted faces. This should heavily reduce any mess it would make.
Now it’s only a matter of enabling smooth shading and adding an edge split modifier. The finished result should look like this.
Now you might be wondering, what would happen if i were to skip all of that and apply the Boolean right away? The result would look like the cone on the left (image below). Compared to the one we made on the right, you can see that it left some nasty shading, and it can get much, much worse on complex models.
This is the workflow i use for making holes and such. Do keep in mind that while it gives nice results, it’s not very suitable for everyday game assets.
It’s true that for standard props it would be overkill to put details on meshes that eat performance and nobody woud notice. I highly prioritize optimization when i create assets for developers and wouldn’t resort to doing this without a valid reason. However, if you were to create a highly detailed showcase to get noticed by EBR senpai, it might just come in handy.
There are many ways to solve a problem. We don’t all eat ice cream the same way, or put our clothes on in the exact same order. In the end, the model will be the same. It all comes down to personal preference.
Manual cutting does not work in the case of the Frustrum pillar. Doing this would give the same result in terms of artifacts as the Boolean modifier on the left cone.
I find that if you take the proper steps before applying the boolean, you can get good results the majority of the time.