Training:

Relevant data for this tutorial:

Step 1: Reimport your already optimised geometry

The optimised geometry can be reimported into a new project or into the already existing optimisation project. For this Tutorial the project of the GD Bracket with different complexities is used.

For a Retransition to a NURBS CAD-Geometry a non-intersected optimisation result is needed. Therefore, a STL-file from the scenario result folder in the workspace is imported.

Documents → Apex Generative Design Workspace→ GD_Bracket_Complexity → Meshless Generative Design Scenario 2 Step 1 (2).v1 → buildSpace_MC_MainData_Loop_64.stl

Take care to choose the right unit system. Projects calculated directly in MSC Apex Generative Design are always calculated in Meters.

For this Tutorial the result file from the second Scenario with a complexity of 20 GB is used.

After importing the non-intersected STL-file the optimisation result is displayed as a Faceted Solid inside the model tree.

Step 2: Mesh to CAD

With the Facet Body to NURBS Geometry Tool under the Geometry Edit Tools the STL-file can be transitioned to a CAD-file. Therefore, the Automatic Size Calculation and the Partition Preview can be kept activated. With the middle mouse button (MMB) the operation can be executed.

In a first step a preview of the partitioned quad mesh is shown.

If the partition looks satisfying the NURBS patch creation can be started by confirming with the middle mouse button (MMB). Depending on the Geometry this step can take some time.

After finishing the status bar in the bottom left displays “NURBS is created based on partitioned Facet Body” and a new solid shows up in the model tree.

From time to time depending on the geometry some NURBS patches can fail. These will be displayed in the status bar as well. If this happens the geometry can be repaired manually.

Step 3: Geometry Cleanup

We recommend to use the Geometry Cleanup Tools after the NURBS CAD-Geometry is created.

Step 4: Creation of functional surfaces and sharp edges with Boolean operations

To create the final CAD-Geometry all functional surfaces and sharp edges have to be created with boolean operations. The best way for this is a boolean intersection between the retransitioned optimisation result and the Design space of the optimisation. A copy of the Design space is desired for the following operation.

With the Transform Tool the Solid of the Design space can be copied by activating the Copy option.

To create one solid without any cells or partitions the boolean merge function for cells has to be used. With this a Solid only for the Intersection with the NURBS Retransition is created.

The next step is a boolean intersection between the created NURBS Geometry of the optimisation result and the edited Design Space solid.

In some cases this intersection fails due to overlaying surfaces from the optimised result and Design space. In the picture below a critical area is displayed.

If this happens the Design Space for the Intersection needs to be manipulated to make a boolean intersection possible. In most cases a reduction of the Design Space for the intersection is successful.

For this part all bore hole radii are increased by 1 mm from r = 5 mm to r = 6 mm.

Furthermore, the surface at the bottom is decrease (pushed) by -0.2 mm (in negative z-direction).

Now, the boolean intersection between the optimisation result and the modified Design Space can be performed.

The last step is to bring back the original dimensions for the bore holes and the down surfaces.

With the Push/Pull Tool all radii can be set back to r = 5 mm.

Moreover, the down surfaces have to be increased by 0.2 mm.

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 which are post processed by milling or other manufacturing post processes.

The finished Geometry can be used in any CAD software and for all further steps like a FE-Reanalysis with MSC Nastran.

The whole MSC Apex Generative Design project with the retransitioned intersected CAD-file can be downloaded here: