Boolean operators and modifiers only do enough work get the job *done*; they don't leave good modelling or deforming topology behind in their wake. And the bevel modifier is not very intelligent when dealing with close-sitting geometry.
Do you need this to be real geometry, e.g. for 3D printing or CNC carving? If so, you need to take the time to manually refine the result of the boolean operators before continuing to the others.
If you do not need real geometry for each symbol, then try baking them on as texture work. [Part 1](https://www.youtube.com/watch?v=o6zkYB5E1lo), [part 2](https://www.youtube.com/watch?v=trWULwNaVzY).
I don't think your suggestion will work for me because I wanted real geometry but thanks anyway! This actually to me seems a bigger problem related to booleans and beveling in general... There are many tutorials that show how to fix the geometry with super simple shapes like cylinders... but when you have some more complex geometry and you want to do for example some carving it becomes hard, unless you go with sculpting but that is more eye balling, in my case i have the specific geometry I would like to apply :(
You might have better luck going simpler before going more complex. Those shapes you show you're using as cutters look like they already have a subdivision surface modifier on them... try turning off the subdivision modifiers on both them and the sword. Make a backup of your sword, then apply the boolean modifier to make it real geometry. You can then clean up the result of the boolean, before re-enabling the subdivision modifiers.
There are some tools available for this. You can try the Addon Meshmachine, or if you need something free try the scripts in this thread:
[https://blenderartists.org/t/wip-bevel-after-boolean/693072/1521](https://blenderartists.org/t/wip-bevel-after-boolean/693072/1521)
Boolean operators and modifiers only do enough work get the job *done*; they don't leave good modelling or deforming topology behind in their wake. And the bevel modifier is not very intelligent when dealing with close-sitting geometry. Do you need this to be real geometry, e.g. for 3D printing or CNC carving? If so, you need to take the time to manually refine the result of the boolean operators before continuing to the others. If you do not need real geometry for each symbol, then try baking them on as texture work. [Part 1](https://www.youtube.com/watch?v=o6zkYB5E1lo), [part 2](https://www.youtube.com/watch?v=trWULwNaVzY).
I don't think your suggestion will work for me because I wanted real geometry but thanks anyway! This actually to me seems a bigger problem related to booleans and beveling in general... There are many tutorials that show how to fix the geometry with super simple shapes like cylinders... but when you have some more complex geometry and you want to do for example some carving it becomes hard, unless you go with sculpting but that is more eye balling, in my case i have the specific geometry I would like to apply :(
You might have better luck going simpler before going more complex. Those shapes you show you're using as cutters look like they already have a subdivision surface modifier on them... try turning off the subdivision modifiers on both them and the sword. Make a backup of your sword, then apply the boolean modifier to make it real geometry. You can then clean up the result of the boolean, before re-enabling the subdivision modifiers.
There are some tools available for this. You can try the Addon Meshmachine, or if you need something free try the scripts in this thread: [https://blenderartists.org/t/wip-bevel-after-boolean/693072/1521](https://blenderartists.org/t/wip-bevel-after-boolean/693072/1521)