Mark,
Welcome to VSP, I hope you'll find it to be useful. I think you'll
find that making the most of VSP requires some substantial departures
from the traditional CAD way of doing things.
There has been a lot of work by diverse groups to connect VSP to CFD.
Every group/tool/application seems to require a slightly different
approach.
The most mature path is to Cart3D, but even with that target, there
are multiple ways to get there.
For an unstructured code like Fun3D/USM3D, I would suggest using the
CDFMesh capability to generate a quality triangle surface mesh and
then go from there. You'll then need to use a volume mesher that can
start from just a surface mesh. Many inviscid tools can do this --
TetGen is open source. If you want to start with viscous layers,
there are fewer to choose from I know AFLR3 from Mississippi State and
Steve Karman's tools from UT Chattanooga can fill this role. Maturing
this workflow has been on my list all year, but I haven't been able to
get to it.
We do have some users who have developed a VSP XSec-file based
approach to convert to Plot3D and then generate Overflow grids. I
don't know the details -- or even who the best contact would be.
However, someone who knows is probably on this list.
STEP output of a watertight surface is on the to-do list, but it'll be
more than a year before it is complete. We're in the process of a
major refactoring and rewrite of some core code. The STEP output will
come after that.
There are no plans for a direct CAD import. The imported geometry
would not be parametric, so there isn't that much utility in doing so.
We can already read in some discrete surface representations (such as
a STL file) and there are plans for assisted parameterization of that
kind of data. That work is more than a year out.
There are no plans to support any sort of fillet/chamfer type
operation. That kind of operation doesn't really fit in with the VSP
way of doing things. So, depending on the fairing, we may be able to
handle it -- but quite possibly not.
There is some very simple control surface support in the Airfoil tab.
It is probably sufficient to use a small deflection to estimate a
control surface derivative, but it isn't appropriate for a high lift
configuration.
If you're doing a high lift wing, you probably have the flap
coordinates as a file. VSP does not force input airfoil data to be
scaled [0,1], so if the slat extends into -x and the flap extends
beyond x=1, no problem. You can create a baseline wing -- usually the
cruise configuration. Then duplicate that wing for each element in
the high lift configuration. Change the airfoil files as appropriate
and you can build the high lift configuration.
You can then use parameter linking to connect the high-lift wings to
the cruise wing. That way, any parameter changes in the cruise wing
will be reflected in the high lift configuration.
The VSP Hangar has an example of this approach (I'm not sure if it is
linked), it should give you an idea of what I'm talking about.
http://hangar.openvsp.org/vspfiles/52
Rob