Geometry Cleanup and Mesh on 2D SHELL Elements Using Hypermesh Radioss

Google drive link for Hypermesh files:



The key objective is to carry out the geometry cleanup operation & ignore holes less than dia 5mm, extract mid surface and create a 2D mesh with target length 5mm, min 3.5mm max 7 mm and assign proper thickness, by creating a generic property.

We have three models for this challenge on which we have to do all the certain things.


1. Import the proper file into Hypermesh Radioss and whenever we save file we make sure that extension is .hm otherwise it won't work next time when we open.

2. Change the visibility mode to the mixed-mode for a proper view of all cons.
Here red lines are single cons, yellow lines indicate connecting three different surfaces i.e. triple cons and we have to convert into green color line double cons.

3. Firstly we do geometry clean up of model 1. In which we check for all the red and yellow lines and convert it into green lines.
To do this job we can use certain commands under the Geometry tab like:
Fill surface, add or remove points, toggle edges all are under Quick edit option. Here according to the question, we can remove all the holes which are less than 5mm dia.
For measuring of any Holes we can use Distance option and its good to check the hole with three points it gives us proper accurate results.

We perform all the operations on all three models one by one in separate files and make sure geometry should be close before moving ahead towards the mid surface extraction.

                                              Model 1 Geometry cleanup

                                               Model 2 Geometry cleanup

                                    Model 3Mounting Bracket Geometry cleanup

4. Now we Extract Midsurface from the Geometry but make sure before creating mid surface delete all the solids which are present in geometry.
We can use Auto Extraction Option for creating the mid surface.
Here we also get to know other extraction options in which we can see max. thickness should not exceeds 6 mm & max. thickness ratio. is 10 otherwise model is not in the shell category, it is in a solid category.

Overview of shell element: General thumb rule for thickness:

Thickness <= 6mm; Represent by shell element

Thickness > 6mm; Prefer solid element over shell element

5. Now we have to do meshing on that mid surface. so for that first, we isolate the mid surface from parent body by using model tab and pid options.
After Creating mid surface we have many other options but here we use Auto mesh option in 2D Window for meshing the whole or one by one surface.

Key tips for meshing the surfaces;

  • For holes, no. of points should be even in number.
  • Match the no. of points both side of edges to get rid of Trias.

6. Check also for Quality Index: here only rectify Minimum & maximum length error. First we assign the Element target length and Minimum & maximum length after that we try to remove all the errors which are present in our Model.

For rectifying errors, we can use cleanup tools option where can use element optimization, split Quad elements, etc.

We do perform all these procedures for all three models for getting the desired results.

                                              Model 1 After meshing

                                          Model 2 After meshing

                                    Model 3 Mounting Bracket After meshing

7. After getting the meshed part we assign thickness to all the models by using the property option which is equal to the thickness of parent geometry.


  • We get to know about the GUI of Hypermesh.
  • Perform Geometry cleanup and learned different methods of doing.
  • Extract mid surface and create a 2D mesh according to given criteria and assign thickness to mesh.
  • Eliminate the min. & max. length errors.

Google drive link for Hypermesh files:



Projects by Jitesh Sahjwani

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The End