Using the stitch contact interfaces tool

The part, feed system and cooling channels should all be meshed. Create a mold using the mold surface wizard, hide the runner system and cooling channel beams and mesh the mold and inserts using the 3D Mold Mesh. You will see a warning in the Mesh Log, instructing you to use the Stitch Contact Interfaces tool.

1. Click (Mesh tab > Mesh panel > Stitch Contact Interfaces), which is in the Mesh drop-down panel, and enter a merge tolerance.
2. Click Show Contact Interfaces to see where there is contact between the various components.
3. Hide the Mold surface (Regions) and Mold surface (Elements), and examine the contact areas carefully.
4. If there is too much contact, shown in red, decrease the merge tolerance. If there is insufficient contact, increase the merge tolerance.
5. When you are happy with the contact area, click Apply, then Close to exit the dialog.
6. Make the Mold surface (Regions) layer visible, and click 3D Mold Mesh again.
7. Check the internal and external edge lengths, then click Mesh Now to create the mold surface mesh.
8. Hide the Mold External Triangles, and check that there is a surface mesh on all the internal components, including the runner system and channels.
9. Show the Mold External Triangles layer again, and click 3D Mold Mesh one final time to create the 3D mold.