topic Re: Converting Complex Mesh model to solid model in Fusion Design, Validate & Document Forum

Converting Complex Mesh model to solid model

Damien_Deline — Fri, 12 Jan 2024 15:43:09 GMT

I have a mesh model with over 2 million facets that I am trying to convert to a solid model . I want to use the "organic" feature for Convert to a Solid because the model is of a human head and there are few prismatic features on the model . But I want to get it right within a couple tries because it takes about 30 mins to generate and I need to use cloud token for the Organic feature . I have done about 3 iterations so far without the Organic feature to make sure I'm on the right track . I have been starting out with the Generate faces feature before converting so i can identify standard features like fillets and flat planes then I am converting to a solid but some of the basic designs like fillets and cylinders are still generating as thousands of triangular surfaces . Can anyone give me a step by step to be successful with this ?

Re: Converting Complex Mesh model to solid model

Warmingup1953 — Fri, 12 Jan 2024 17:04:37 GMT

Can you share your Mesh?

Re: Converting Complex Mesh model to solid model

Damien_Deline — Fri, 12 Jan 2024 18:52:36 GMT

I, unfortunately, cannot without an NDA .

Re: Converting Complex Mesh model to solid model

TrippyLighting — Fri, 12 Jan 2024 20:06:08 GMT

@Damien_Deline wrote:

I, unfortunately, cannot without an NDA .

Then you put yourself in a peculiar spot 😉

You can achieve the same, or better results with InstantMeshes, a free software.

I created a tutorial a few years ago that explains some of the workflows and caveats.

Re: Converting Complex Mesh model to solid model

etfrench — Sat, 13 Jan 2024 21:58:04 GMT

What operations do you need to do to the mesh? Will the current mesh tools accomplish these?

Re: Converting Complex Mesh model to solid model

Damien_Deline — Tue, 16 Jan 2024 16:52:32 GMT

This is exactly what i was looking for ! I appreciate it , I will respond back soon after applying it .

Re: Converting Complex Mesh model to solid model

Damien_Deline — Tue, 16 Jan 2024 16:51:42 GMT

I need to make a machining fixture for the part so i will be doing something like a Combine-cut function with the body then I need to machine the part so I need to be able to select prismatic geometries (The mess is a mixture of organic as well as prismatic features) within the manufacturing environment.

Also , one of the major issues currently is the number of facets on the mesh is causing the computer to bog down even though we have 64gigs of DDR5 as well as Intel Core i9-12900K 5.2ghz

Re: Converting Complex Mesh model to solid model

Damien_Deline — Wed, 17 Jan 2024 14:54:23 GMT

That worked great ! i had some minor issues with some sharp edges that ended making me create nurbs surfaces instead of solids but after about 15 mins of surface modeling/repairing it was in perfect shape. It went from 2.8mil facets to 2.1k , great stuff ! Thank you !

Re: Converting Complex Mesh model to solid model

KevinMacDonald — Wed, 19 Nov 2025 08:11:41 GMT

Hello!

I followed your tutorial and used MeshMixer and InstantMeshes to boil an STL with 1.1 million faces down to 50,000, and pull it into Fusion. But unfortunately the Form --> Repair Body function always seemed leave a few remaining errors that prevented me from finishing the Form. The STL is intended for 3d printing, and when I send it to Bambu Studio with all 1.1 million faces there is no problem slicing it. I just can't ever get it into a true solid body in Fusion. I know that the Design Extension has the "organic" mode for converting a mesh to a solid, but I'm wondering it that will also fail.

Re: Converting Complex Mesh model to solid model

TrippyLighting — Wed, 19 Nov 2025 14:32:46 GMT

If you could create a new thread and post the model, perhaps a zipped original .stl file I can look into it.

Re: Converting Complex Mesh model to solid model

KevinMacDonald — Wed, 19 Nov 2025 22:46:37 GMT

Thank you for offering! I'm not certain if technically I should do that, as this was purchased from an artist on line. Could I send it to you privately so it doesn't wind up on the internet at large?

Re: Converting Complex Mesh model to solid model

TrippyLighting — Thu, 20 Nov 2025 01:33:59 GMT

If you have a Dropbox or similar account, please feel free to send me a download link via PM.

Re: Converting Complex Mesh model to solid model

johnsonshiue — Thu, 20 Nov 2025 16:28:19 GMT

Hi Kevin,

I have seen similar mesh model before. It is like a terrain survey. I would try reducing the complexity (number of elements) in Mesh Design environment. And use Repair workflow to identify problems. Stitch the mesh before converting to a Tspline body. Please feel free to share the file with me directly at johnson.shiue@autodesk.com. I would like to understand the issue better.

Many thanks!

Re: Converting Complex Mesh model to solid model

laughingcreek — Thu, 20 Nov 2025 23:21:00 GMT

@KevinMacDonald wrote:...as this was purchased from an artist on line. ...

There is a very good chance that the artist created the model as a quad mesh in a polymodeler (maya, blender, etc) . If you could talk them into giving you the original quad mesh your life will be easier.