[SnyderFoam]

I am trying to expand upon a simulation that I completed a few months ago....(creating a mesh for a small object <1m in length.)

This time I am trying to add my air ducting. The ducting will have a face designated for two fan inlets, outlet location, and an internal object which will impinge on the air flow.

Eventually this will be a conjugate heat transfer model, but for now I just want to show how air moves in the system.

I began by making two steps files. One for the solid object (red in image) and a volute for the the air (blue in image). The volute representing the air was created in onshape CAD with a boolean operation then saved and imported into Salome Meca 2021 as a STEP file.

I have tried previously successful mesh setups on these objects but can not seem to get a good mesh. It either hangs on 0%, fails with surface feature errors, or takes far too long to finish meshing (ends without success).

What checks could I do to see if my troubles are geometry based vs mesh parameter based?

[SnyderFoam]

Here is an example of my woes......

[SnyderFoam]

Okay, so the CAD I imported was apparently throwing off the mesh. I cleaned up the import steps and everything meshed great now. I have attached photos of the isolated mesh views.

The new problem is when I try to run ideasUnvToFoam. I get the error....

Constructing mesh with non-default patches of size:
inlet 167
outlet 350

--> FOAM Warning :
From function Foam:olyMesh:olyMesh(const Foam::IOobject&, Foam:ointField&&, const cellShapeList&, const faceListList&, const wordList&, const wordList&, const Foam::word&, const Foam::word&, const wordList&, bool)
in file meshes/polyMesh/polyMeshFromShapeMesh.C at line 595
Found 87387 undefined faces in mesh; adding to default patch.
Adding cell and face zones
Cell Zone fluid 308045
Face Zone walls 58983
ideasUnvToFoam: ideasUnvToFoam.C:1287: int main(int, char**): Assertion `nouveau > -1' failed.
Aborted (core dumped)