Reno Genest
Ansys Employee

Hello Sushil,

I am not sure I fully understand the problem. You have 2 sandwiches instead of one? Could you send an image? 

How is this part built in real life? How are the layers applied? How is the foam positioned? If you follow the manufacturing procedure in ACP, you should get good results.

The oriented element sets will determine where the foam is located.

Let me know how it goes.