Ok skoolbus, after reading your most recent post where you mentioned I might have made a sharp edge in your model, I re-looked at the model and realized a lot of mistakes on my part my advice. I was just focusing on your problems you posted about and didn’t notice the biggest problem you are having in modeling this, IMO.
You basically have a square object that you are rounding out by using the subsurf modifier and cranking up the subsurf levels. Don’t do that… :no: The iPhone has rounded corners, so model them as round corners and don’t use subsurf to round them for you. It’s kinda like trying to fit a square block in a round hole, sure it doesn’t fit, but with a sledge hammer you can make it fit…
If you’re going to remodel this thing, then do it right and without a sledgehammer. You have a good basic shape, and a real nice render, I must say, so use that as a guideline for the remodel. Go for the basic shape first, without subsurf and then work on details and refine from there.
I don’t know an easy way to show you how to model this, it may seem easy and in fact it is easy, once you know the basics, but diving into it head first without the basics will be frustrating. I would start with a corner and a circle to make the corner. A 16 vert circle, delete 3/4 of the circle and work on moving verts around like so:
Now you have a rounded corner, and work from there to form the face plate.
To answer your questions, a mesh can intersect another mesh object without any problems. The only time it will be a problem is if you have 2 meshes in exactly the same place - think of a plane, then duplicate the plane and not moving the 2nd one at all. Now they both occupy the same space and will cause a render error. You can stack objects on top of each other and allow them to intersect each other, it will be fine.
I didn’t get into the power switch, and who ever said it can’t be done is wrong. And my renders were with Luxrender.
Post back here, and I’ll give you a hand… yet again, it’s late…