A method for the rapid construction of meshes over intersecting triangulated shapes is described. The method is based on an algorithm that automatically generates a surface mesh from intersecting triangulated surfaces by means of Boolean intersection/union operations. After the intersection of individual components is obtained, the exposed surface parts are extracted. The algorithm is intended for rapid interactive construction of non‐trivial surfaces in engineering design, manufacturing, visualization and molecular modelling applications. Techniques to make the method fast and general are described. The proposed algorithm is demonstrated on a number of examples, including intersections of multiple spheres, planes and general engineering shapes, as well as generation of surface and volume meshes around clusters of intersecting components followed by the computation of flow field parameters.