Abstract: A system and method of generating a converged mesh is disclosed. In one embodiment, the method includes identifying a plurality of geometrical mesh parameters for a design component, obtaining order of significance for the identified geometrical mesh parameters using a first statistical technique based on one or more desired convergence parameters, obtaining number of grid elements for each of the geometrical mesh parameters by applying a second statistical technique on the obtained order of significance, and generating the converged mesh using the obtained number of grid elements for each of geometrical mesh parameters.

Abstract: A method for thermoforming a part is provided. The method includes cutting a blank and masking at least one side of a desired surface of the blank with a flow-controlling material. The method also includes heating the masked blank to a forming temperature and forming the blank to achieve a desired contour of the part.