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To create the final CAD-Geometry all functional surfaces and sharp edges have to be created with boolean Boolean operations. The best way for this is a boolean Boolean intersection between the retransitioned optimisation result and the Design space of the optimisation. A copy of the Design space is needed for the following operation.
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The next step is a Boolean Intersection between the created NURBS Geometry of the optimisation result and the edited Design Space solid.
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In some cases, this intersection fails due to overlaying surfaces from the optimised result and Design Space.
If this happens the Design Space for the Intersection needs to be manipulated to make a boolean Boolean intersection possible. In most cases a reduction of the Design Space for the intersection is successful.
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The result is an intersected CAD-Geometry with all functional sharp edges and surfaces. At this point it is also possible to create Machining Allowances on functional surfaces if this was not already considered and done in the optimisation.
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Workaround: Boolean Subtraction
For some really complex parts it might not be directly clear which areas are the critical ones for the intersection. In these cases, Boolean Subtractions can help to create the functional surfaces and sharp edges.
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