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This is the old design where I can mesh and run static simulation with no problem.
work
This is the modified design, I can never get it to mesh. If I try to reduce the mesh size, it takes too long to run (more than 10 min). and fail at the end.
I would try to pinpoint the exact geometry Solidworks is having issues with. I reckon since you have an old and new model this is some newly added geometry. Then you can decide if this geometry is essential for the simulation. It seems to me you have alot of "unused material" in the part where there is no stress at all (!). It is time consuming to simulate and mesh these useless areas.
So you could also only model the portion that is critical for the stress simulation.
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