Generative Design reconstructed parts intersecting with Excluded geometry areas

[JSar]

Hello,

I am trying to create optimized parts for AM. During the initial optimization (pic 1), the part looks very good and respects the Excluded Geometry bodies, ie. keep out areas.

However, when I generate the result to reconstructed part (pic 2), it will create shapes intersecting with Excluded Geometry areas. In this example, I cannot attach the required fasteners to final design since the organic blobs are blocking it.

I thought that build direction could have something to do with it, so I flipped it to not have any internal "ceilings", or bridging, in the design. Same result (pic 3).

I have tried to change material, material spreading, forces, output resolution level, excluded geometry design etc (pic 4). The same challenge repeats, final reconstructed design does not respect my excluded geometry.

I am running it on CREO Parametric  10.0.1.0 with GTO & AAX extensions.

All tips are welcome & appreciated!

[ProFeature]

Hi @JSar 

Can you share the model?

-Thnaks

[JSar]

Hi, I sent it to you as private message.

Thanks!

[ProFeature · Accepted solution]

Hi @JSar 

I use Creo 11, and I had the same hole issue you did.

I recommend that you use the Boolean operation to remove the excluded geometry (KEEPOUT body) without using it in GD.

When I tried this technique, I did not encounter your problem.

Please note you Preserved geometry is partially outside the starting geometry. This is something you should fix, but it has no bearing on the hole issue you raised in the topic.

-Thanks,

[JSar]

Thanks for your fast reply & bug confirmation on Creo 11.

I subtracted the excluded geometry from the starting geometry and it worked well! No more blobs, perfect straight surfaces for attaching the fasteners. Many thanks - is this in general a way you would propose for (complex) generative designs?

I could not find geometry outside of my Starting Geometry in the original design. Probably something got changed by accident when creating a relation-free model.

PS. it's kind of a shame that the bug existed for you as well, I was actually hoping that Creo 11 had less of these hiccups in Generative Design. We are going to move to 11 soon.

[ProFeature]

Hi @JSar 

Have you tried opening a support case for your topic?

-Thanks

[JSar]

Hello @ProFeature , thanks for the tip!

I just opened a support case. Meanwhile I will use your workaround so I can proceed with the designs.

[Dale_Rosema]

Just a guess, but are the plus signs there to exclude those surfaces? If so, do you need to add those markers to the flat bolt surfaces that are being distorted?

[JSar]

Hi Dale, those plus-looking objects are symbols for the Fixed Constraint. They are for the preserved geometry and in the edge of my Design Space. If you compare the initial optimization result in green (pic 1) and reconstructed part (pic 2), the have no problems at all.

It's the red parts, excluded geometry that is the challenge. The reconstructed part will always overlap with them