Cannot Generate Mesh for Modal Frequency Analysis on Generative Design Part

[Anonymous]

Hi All, 

I am unable to mesh a generatively designed drone frame I have in Fusion360.

Where the organic geometry meets the preserve geometry is quite sharp often and I am unable to place rads on these areas. I've exported the design as an STL and used Mesh Mixer to smooth areas out.

However, I am unable to convert back from STL to solid geometry (SOLIDWORK/FreeCAD have both failed to convert the STL back into a part/STEP file and I imagine file size would become unmanageable).

My plan was therefore to perform Modal Analyses FEA on the original geometry, pictured below.

However, at any element size the mesh fails to be created. I have also tried to create a mesh on SOLIDWORKS and Creo Parametric and faced the same issues.

Here is a link to the file: https://a360.co/3bFV3sn

Has anyone got any suggestions? Previous forums raising meshing issues seem to always be rectified by simplifying/modifying geometry. For this case, it isn't practical/possible to modify the geometry due to being a single generatively designed component - when I try to modify individual faces of the GD, my PC crashes, which is what forced me into using meshmixer in the first place.

Hopefully someone can help!

Many thanks,

Andrew

[Anonymous]

To @Anonymous,

Hi 

Andrew

The image you have shared, mentioed the places which is having issue while creating mesh.  You can go back to Model workspace and in history timeline you can go in form tool and edit the red-flgged places. This will help you in mesh generation. Or you can create mesh design as output from generative design workplace.

In one point you mentioned that you are unable to conver STL to solidbody, you can try STL to Brep in Fusion which will help you achieve what you want.

Thank you.