Why is my resulting shape extending beyond the Design Space with noIntersection?

The optimisation has a fully automated smoothing algorithm integrated which is very important to generate a good & printable surface. This step is executed after every iteration, so that every iteration delivers a fully functional and geometrically correct result.

In the first iterations the optimisation runs on a very coarse resolution level and the algorithm smooths these to get a result. With the Advanced User Setting command noIntersection this usually doesn’t lie fully within the Design Space and is not yet a ready-to-use result. As the optimisation continues and moves further along through the resolution levels, the elements get finer and so does the surface with the help of the smoothing. Step by step the surface moves closer to stay within the given Design Space. However, because of the smoothing the edges of the functional surfaces aren’t as sharp as they are supposed to be and there are areas in which the result slightly oversteps the Design Space limitations. To realize the sharp edges and get the finished structure an intersection needs to take place after the optimisation run is finished. More information regarding the manual intersection in MSC Apex Generative Design here.