Yeah, it’s all clear now. The Thicken Shell Mesh tool as well as the standard hex meshing tools can achieve quite a lot when combined with translation/rotation (and patterns), merging coincident nodes and some other tools as shown here or in Matej’s new video.
Node coincidence indeed isn’t always needed, but I would say that it’s desired in the majority of the cases.
right, merging coincident nodes for single part is recommended to avoid any unexpected results due to some constraint or tied contact existed and collide with penalty contact. An original example is different case; it’s usually a baseplate with steel beam connected by welding.
i’m keep the face connected to conformal also, but sometimes not easily to achieved, not much testing in new feature of number element edge in mesh setting.