Final CAD fix (hopefully)
 

Finally, I got a smoothed surface mesh from the Octree mesher of the required element quantity and distribution and without any messages about holes :D. I haven't gone on and generated the TGlib AF Delaunay and Prisms just yet as the Octree was left to run overnight and I ant to get this issue fixed too re-run the Octree.

On inspection of the surface mesh at the fuselage/wing trailing edge interface I noticed 2 small curves which ICEM has followed with mesh elements (only about half a dozen elements). These 2 curves are in the original IGES file but should not be there. I've tried deleting them and re-running Build Topo but ICEM is finding them again. So they must be due to the surface.

The surface image just shows the perspective that the zoomed-in wireframe image is viewed from and the yellow lines are due to me trying different things with the Build Topo and not in the final mesh. The wireframe image shows the wing trailing edge with the 2 curves (bold red) and the trailing edge surface (thin orange). So how can I get the 2 curves to follow the straight trailing edge surface? I think this needs to be done with one of the Geometry tools rather than a tolerance setting, but I've had no success with deleting/merging/creating surfaces.

Thanks.

No need for a geometry based solution.
 

This is a case of how you think about it... Geometry is a problem for you, but the Octree doesn't care about the geometry as much as you do.

So, next time, you can just delete the curves and not bother to re-run build topology. It just means you won't have nodes lining up along that surface edge... do you actually need the elements to line up there? Lining up elements forces them into certain shapes based on the geometric constraints. This limits quality, etc.

I would say Octree only needs curves at the boundaries of sharp features and the perimeter of boundary conditions...

So, just delete the curves (and points for that matter) that do not mark the edges (and corners) of sharp features and boundary conditions...

Now, as for you existing mesh, I guess you won't want to remesh it... Just go into Edit Mesh => Move Nodes, and change the association of those curve projected nodes to "surface projected". This will free them of the silly curves. You could delete line elements also. Then run the smoother again and let it do its thing.

Sorry, I couldn't provide a geometry based solution. Hopefully this is better. If this really is the boundary of an important boco, let me know and we can work thru that.

Best regards,

Simon

Why now a Delaunay fault?
 

Okay, I've now managed to get a checked, smoothed surface mesh from the Octree mesher with no holes or strange elements as posted above at about the required element quantity and distribution. The octree mesh took +8 hrs to run (not sure total time as I left the PC running overnight from a 7am start) and ended with a mesh of about 23 million elements (2 million surface elements).

I then ran the Delaunay mesher (with TGlib and Use AF) and it finished in a matter of minutes with a volume element count of about 5 million as shown in the image. Clearly it didn't work. Why? I don't know what or why stuff has gone outside of the domain when I started with a checked, smoothed surface mesh. Next is how can this be fixed? I was expecting this part to be straight forward.

Thanks.

Hmmm...
 

I have no idea why it would do that... Did you run all the checks before hand (no single edges, overlapping faces, etc.)? Have you tried any other methods (Standard Delaunay or Advancing Front?)

Define a Material Point and used it for mesher.