Incomplete offset generation and meshing errors


I am trying to generate an offset of 0.2-0.5mm on a volume. Using a 0.5mm offset causes error “Offset exceeds radius”. Using a 0.3 and 0.4mm offset causes incomplete offset (please refer to the image below; green volume is the base and yellow volume is the offset).

Using a smaller offset causes node and edge overlap while meshing and the tet meshing terminates. Could you please tell me how to solve this issue?

Thank you


I have tried using regularize and reduce volume tools but it doesn’t seem help. Also, when I try to use boolean operations, there is an error “ACIS API message = Boolean could not determine the relationship between an edge of one body and a face of other body”.



Hi Nilay,

Is it possible for you to post your model here along with the commands that you use to generate the problem? I was talking to the tetmesh developers last week and they did report that they have had reports or problems tetmeshing very thin volumes. They are working on a solution.