Hey folks,
I’m running into a geometry issue in SolidWorks 2024 that’s messing up my mesh once I move the model to Abaqus 2024.

I’ve got an exemplary setup made of surface bodies:

• (grey) an outer hexagonal shell with slightly curved walls,

• (yellow) and several sin(x)*sin(y)-shaped inner walls arranged radially inside.

The issue: the inner walls slightly poke through the inner surface of the outer shell, which causes overlapping surfaces and meshing errors in Abaqus (see picture 2).

Right now I’m using Trim Surface, which actually works pretty well — but it leaves tiny intersections where the inner surfaces go just a bit beyond the outer wall. I basically need a way to make those inner walls stop exactly at the inside of the shell — touching, but not penetrating.

Has anyone found a reliable way to align and trim surfaces from different parts so they meet perfectly? Ideally something that still exports cleanly as a STEP file for Abaqus meshing.

Appreciate any advice!

(sorry for the bad quality of the screenshots)