Create Core after composite optimization

Kay Overberg

Hi there, 

I am following the composite optimization tutorial of a formula-student monocoque. After finishing the shuffle optimization step I was wondering if there is any way how I can create the inner shape of my model for later manufacturability with a wax form.

I have to explain my model. I am basically optimizing a tube with fixed outside dimensions of 40mm x 40mm. The elements normals are facing inwards, so the plies are also created in the tube. 

So now if I want to create a solid core with a wax material (not a rohacell foam core like in the tutorial), it is hard to get the dimensions just like the optimized plies if I manually want to do a CAD-model, because the thicknesses and shapes are so different from each other. 

 

So my first question is, if there is any function in Hypermesh, how to automatically create such a specific wax core for later manufacturability, where the plies are applied on top of?

 

My second question is, if I would use the rohacell foam core, is it possible to just extract the dimensions of this core into an CAD-Model for later manufacturability?

 

Thanks for helping

 

Kay