The Casimir free energy for 2d gratings separated by a vacuum slit is expressed in terms of Rayleigh coefficients, a novel general approach valid for arbitrary 2d surface profiles of gratings is outlined. The normal Casimir force in the system of two identical Si gratings with 2d sinusoidal surface profiles separated by a vacuum slit is computed for several amplitudes of surface profiles, distance dependence of the force is studied. A comparison with results for flat boundaries is performed.