Challenge

Project-2-Meshing of Door Inner Panel Challenge

Aim : Mesh the given door inner panel as per quality criteria given in the question and element size.

Procedure :

This is the CAD image of given door inner panel.
This is big and complicated part thus it is advised to divide this part in small no of parts.
So, make cuts along the surface and divide the component so that it can be easily approched.
This is a plastic part, so it has varying thickness.
Because of that while extracting mid surface it often gets distorted.
Thus, it is a better practice to create the mid by auto extraction method as well as offsetting the surface or elements wherever auto mid surface is distorted.
So, where there is mid surface is extracted properly keep that surface and wherever it is not proper delete that much surface and recreate it.
As we proceed furthur make the habit of separating the surfaces as per thicknesses, so that it won't create mess at last while assigning thickness.
In order to separate the surfaces and elements, create separate collectors and organize the surfaces as per thickness.
Extend the elements of ribs to the base surface and align it properly. Make sure all elements are connected to each other.
In this component, there are many ribs or features which have varying thickness along its cross section so at such cases take the average of the thicknesses,

As per told in the question, this area has some geometry issue so modeling it in 2D would be difficult.

So, we made this area flat because in this area our main objective is to capture the surface. Now, we can model this in 2D.

Capture this features like this cross because it is not possible to model this features in 2D.
Now, its time to deal with failed quality.
First of all set the quality criteria given in the question.
Then, clear all the failed quality elements.
There will be some situations where whether we have to keep the failed quality elements or the geometry will not be captured properly.
So, in such cases we can accept failed elements.

As shown here we should accept the failed elements otherwise the ribs will not be captured properly.

Result :

At the end of this project, can model the plastic part confidently.
Got to know how to mesh model using both the manual and auto techniques of meshing and mid surface extracting.

Ship work like this
in your own course.