Fuse Mesh

Use the Fuse tool to connect close proximity, overlapping and intersecting parts.

Input assemblies can have intersecting/partial intersecting parts, overlapping parts, or close proximity parts.

  1. Open the Fuse tool by clicking Mesh > Fuse from the menu bar.
  2. Use the Source entities selector to select source entities.
    Source entities will move to the target.
  3. Use the Target entities selector to select target entities.
    Target entities will not move.
  4. Decide whether to perform Open Shell or Close Shell fusing.
    The fuse algorithm treats open shells (not closed input) and closed shells (water tight shells) differently.
  5. Define additional Open Shell and Close Shell fusing options accordingly.
    Options vary based on the fusing type selected.
  6. Click Fuse to start the fuse operation.

Open and Close Shell Fusing Options

The following tables list options and actions for the Mesh > Fuse dialog box.

Open Shell Fusing
Option Action
Proximity Search Threshold Type the maximum search distance to find proximity elements between source and target into this field. Fusing will be performed between them.
Note: You are not required to enter a precise distance, but it is recommended that you do not define too big of a value compared to the average distance between the source and target in order to avoid performance issues.
Perform Remesh Select this checkbox to remesh elements near the connection based on the user-defined parameters.

Triangle element inputs of the first order will be remeshed. Quad element inputs will be remeshed with mixer elements.

Feature Angle Type the feature angle for the remeshed elements to be captured into this field.
Connect Source Free Edge Only Select this checkbox to connect only the free edges within the user-defined proximity threshold.
Fusing Direction Select a direction to which the source will be projected to the target:
  • Along Source Normal: Choose this option to project source elements to the target based on the source element normal or the shortest distance direction from the source.
  • Along Source Edge Tangent: Choose this option to project proximity source elements in a tangential direction to the source. Tangency is only calculated for free edges. For other inputs, it will project to the target based on shortest distance direction from source.
Create Patch at Connection Select this checkbox to create new patch elements between source and target. If this option is unchecked, source element nodes will be projected and stitched to the target.
Remove Redundant Patches from Target Select this checkbox to remove redundant patches after fusing is performed that are within the user-defined patch maximum width factor. The value of the maximum width factor is calculated by multiplying the factor with the proximity search threshold.
Snap to Features Select this checkbox to fuse source elements to target elements if the features fall within the user-defined feature snapping tolerance factor. The value of the snapping tolerance is calculated by multiplying the factor with the proximity search threshold.

This feature includes free edge, non-manifold edges (t-connection / x-connection), and features based on the feature angle defined in preferences.
Close Shell Fusing
Option Action
Proximity Search Threshold Type the maximum search distance to find proximity elements between source and target into this field. Fusing will be performed between them.
Note: You are not required to enter a precise distance, but it is recommended that you do not define too big of a value compared to the average distance between the source and target in order to avoid performance issues.
Keep Interface Select this checkbox to keep common shells between source and target as they are. Uncheck to remove common shells.


Figure 1. Keep Interface Enabled


Figure 2. Keep Interface Disabled
Maximum Search Angle Type the maximum angle value that is used to detect close proximity between the source and target into this field.
Fusing Direction Select a direction to which the source will be projected to the target:
  • Along Source Normal: Choose this option to project source elements to the target based on the source element normal or the shortest distance direction from the source.
  • Along Source Edge Tangent: Choose this option to project proximity source elements in a tangential direction to the source. Tangency is only calculated for free edges. For other inputs, it will project to the target based on shortest distance direction from source.
Remove Redundant Patches from Target Select this checkbox to remove redundant patches after fusing is performed that are within the user-defined patch maximum width factor.
Note: This is only useful in cases of open shells.
Collapse Patches Select this checkbox to collapse created patches and directly connect the source nodes to the target nodes. When enabled, you can select a destination component for patch: Source Component, Current Component, or New Component.


Figure 3. Collapse Patches Enabled


Figure 4. Collapse Patches Disabled
Perform Remesh Select this checkbox to remesh elements near the connection based on the user-defined parameters.

Triangle element inputs of the first order will be remeshed. Quad element inputs will be remeshed with mixer elements.

Number of Layers Type the number of additional layers next to the intersect edge that need to be remeshed into this field.
Feature Angle Type the feature angle for the remeshed elements to be captured into this field.
Growth Rate Type the growth rate for remeshing into this field.

Fuse Mesh Examples

The Fuse tool can be used with several types of analyses where mesh connections are required.

CFD Fluid Analysis Model Preparation

Create a water tight, fluid volume for CFD analysis by connecting shell and solid parts.


Figure 5.

Thermal Analysis Model Preparation

Prepare the model for thermal analysis by connecting closed shells across the assembly.


Figure 6.

Electromagnetic Analysis Model Preparation

Define connections across part assemblies by connecting the midmesh of shell parts.


Figure 7.