Is anyone able to mesh this?

[CosmoKramer]

(v2.4.0) I’m trying to mesh a model but getting an error for the “Insulation” part: “Mesh generation failed for part Insulation. Check the geometry and/or adjust the meshing parameters.”

I recall facing a similar error with another equally large model, and I restarted the programme and closed all background processes, and it worked. I also did manage to mesh a smaller ‘sample’ of this model with no probs. Want to know if this is a hardware problem or if there’s something wrong with the geometry.

The parts that I want to mesh are: InnerBlock, Slab, Insulation, OuterBlock (compound part), Cladding (compound part), and AnglesAndScrews (compound part). I’ve tried increasing the max size but that didn’t help.

Here’s the PMX file – would appreciate any help on how to solve this.

[FEAnalyst]

The connection between the slot and the hole seems to be problematic:

[ViV]

There is overlapping geometry in the Insulation part.

After removal (I did not check the mesh quality).

Mesh part by part.

310.pmx (1.3 MB)

[FEAnalyst]

That’s the slot I pointed out, but the question (for the OP, of course) is if it has to be modeled this way (or at all).

There’s still another problem with this geometry, though - no cutout here:

@CosmoKramer Please have a look at the Geometry validity and Geometry simplification chapters here (when it’s back online - I can’t access it now): https://wiki.freecad.org/FEM_Geometry_Preparation_and_Meshing

[CosmoKramer]

Thanks @FEAnalyst and @ViV

I finally figured out the root cause of this and why the mesh for the sample worked but that of the full model didn’t: I was using Compound in FreeCAD to repeatedly copy one group of objects (block+angles+screws+cladding). For some reason, PrePoMax wasn’t recognising some of the holes that these objects would have as a result of other objects penetrating them (one thing I love about PrePoMax is that, normally, it is able to ‘draw-up’ holes where there is penetration, without me having to do it manually).

So instead of Compound I used BooleanFragments > Standard (tried CompSolid and Separate but they weren’t as ‘clean’) and that did it. Here are some images and here’s the link to the fixed PMX file.