Dealing with Inconsistent Mesh Thickness — Lesson 8

When using the Cartesian meshing option in the Mechanical Additive tool, what is the cause of the following error message? “Element 'x' (corresponding to layer n) has a mesh thickness of 'y' that is not consistent with the other elements (thickness='z'). The mesh must have the same thickness for each layer.”

This can happen when the interface between the build body and supports is nonplanar. One workaround is to merge the build and support(s) into a single multibodied part. The build and supports are still distinct bodies, but they will now share common nodes at interface.