Methodology for automatic recovering of 3D partitions from unstitched faces of non-manifold CAD models

Data exchanges between different software are currently used in industry to speed up the preparation of digital prototypes for Finite Element Analysis (FEA). Unfortunately, due to data loss, the yield of the transfer of manifold models rarely reaches 1. In the case of non-manifold models, the transfer results are even less satisfactory. This is particularly true for partitioned 3D models: during the data transfer based on the well-known exchange formats, all 3D partitions are generally lost. Partitions are mainly used for preparing mesh models required for advanced FEA: mapped meshing, material separation, definition of specific boundary conditions, etc. This paper sets up a methodology to automatically recover 3D partitions from exported non-manifold CAD models in order to increase the yield of the data exchange. Our fully automatic approach is based on three steps. First, starting from a set of potentially disconnected faces, the CAD model is stitched. Then, the shells used to create the 3D partitions are recovered using an iterative propagation strategy which starts from the so-called manifold vertices. Finally, using the identified closed shells, the 3D partitions can be reconstructed. The proposed methodology has been validated on academic as well as industrial examples.This work has been carried out under a research contract between the Research and Development Direction of the EDF Group and the Arts et Métiers ParisTech Aix-en-Provence

Plate-impact loading of cellular structures formed by selective laser melting

Porous materials are of great interest because of improved energy absorption over their solid counterparts. Their properties, however, have been difficult to optimize. Additive manufacturing has emerged as a potential technique to closely define the structure and properties of porous components, i.e. density, strut width and pore size; however, the behaviour of these materials at very high impact energies remains largely unexplored. We describe an initial study of the dynamic compression response of lattice materials fabricated through additive manufacturing. Lattices consisting of an array of intersecting stainless steel rods were fabricated into discs using selective laser melting. The resulting discs were impacted against solid stainless steel targets at velocities ranging from 300 to 700 m s-1 using a gas gun. Continuum CTH simulations were performed to identify key features in the measured wave profiles, while 3D simulations, in which the individual cells were modelled, revealed details of microscale deformation during collapse of the lattice structure. The validated computer models have been used to provide an understanding of the deformation processes in the cellular samples. The study supports the optimization of cellular structures for application as energy absorbers. © 2014 IOP Publishing Ltd

Procedural function-based modelling of volumetric microstructures

We propose a new approach to modelling heterogeneous objects containing internal volumetric structures with size of details orders of magnitude smaller than the overall size of the object. The proposed function-based procedural representation provides compact, precise, and arbitrarily parameterised models of coherent microstructures, which can undergo blending, deformations, and other geometric operations, and can be directly rendered and fabricated without generating any auxiliary representations (such as polygonal meshes and voxel arrays). In particular, modelling of regular lattices and cellular microstructures as well as irregular porous media is discussed and illustrated. We also present a method to estimate parameters of the given model by fitting it to microstructure data obtained with magnetic resonance imaging and other measurements of natural and artificial objects. Examples of rendering and digital fabrication of microstructure models are presented

Geometric Modeling of Cellular Materials for Additive Manufacturing in Biomedical Field: A Review

Advances in additive manufacturing technologies facilitate the fabrication of cellular materials that have tailored functional characteristics. The application of solid freeform fabrication techniques is especially exploited in designing scaffolds for tissue engineering. In this review, firstly, a classification of cellular materials from a geometric point of view is proposed; then, the main approaches on geometric modeling of cellular materials are discussed. Finally, an investigation on porous scaffolds fabricated by additive manufacturing technologies is pointed out. Perspectives in geometric modeling of scaffolds for tissue engineering are also proposed

From 3D Models to 3D Prints: an Overview of the Processing Pipeline

Due to the wide diffusion of 3D printing technologies, geometric algorithms for Additive Manufacturing are being invented at an impressive speed. Each single step, in particular along the Process Planning pipeline, can now count on dozens of methods that prepare the 3D model for fabrication, while analysing and optimizing geometry and machine instructions for various objectives. This report provides a classification of this huge state of the art, and elicits the relation between each single algorithm and a list of desirable objectives during Process Planning. The objectives themselves are listed and discussed, along with possible needs for tradeoffs. Additive Manufacturing technologies are broadly categorized to explicitly relate classes of devices and supported features. Finally, this report offers an analysis of the state of the art while discussing open and challenging problems from both an academic and an industrial perspective.Comment: European Union (EU); Horizon 2020; H2020-FoF-2015; RIA - Research and Innovation action; Grant agreement N. 68044

Query processing of geometric objects with free form boundarie sin spatial databases

The increasing demand for the use of database systems as an integrating factor in CAD/CAM applications has necessitated the development of database systems with appropriate modelling and retrieval capabilities. One essential problem is the treatment of geometric data which has led to the development of spatial databases. Unfortunately, most proposals only deal with simple geometric objects like multidimensional points and rectangles. On the other hand, there has been a rapid development in the field of representing geometric objects with free form curves or surfaces, initiated by engineering applications such as mechanical engineering, aviation or astronautics. Therefore, we propose a concept for the realization of spatial retrieval operations on geometric objects with free form boundaries, such as B-spline or Bezier curves, which can easily be integrated in a database management system. The key concept is the encapsulation of geometric operations in a so-called query processor. First, this enables the definition of an interface allowing the integration into the data model and the definition of the query language of a database system for complex objects. Second, the approach allows the use of an arbitrary representation of the geometric objects. After a short description of the query processor, we propose some representations for free form objects determined by B-spline or Bezier curves. The goal of efficient query processing in a database environment is achieved using a combination of decomposition techniques and spatial access methods. Finally, we present some experimental results indicating that the performance of decomposition techniques is clearly superior to traditional query processing strategies for geometric objects with free form boundaries

BSP-fields: An Exact Representation of Polygonal Objects by Differentiable Scalar Fields Based on Binary Space Partitioning

The problem considered in this work is to find a dimension independent algorithm for the generation of signed scalar fields exactly representing polygonal objects and satisfying the following requirements: the defining real function takes zero value exactly at the polygonal object boundary; no extra zero-value isosurfaces should be generated; C1 continuity of the function in the entire domain. The proposed algorithms are based on the binary space partitioning (BSP) of the object by the planes passing through the polygonal faces and are independent of the object genus, the number of disjoint components, and holes in the initial polygonal mesh. Several extensions to the basic algorithm are proposed to satisfy the selected optimization criteria. The generated BSP-fields allow for applying techniques of the function-based modeling to already existing legacy objects from CAD and computer animation areas, which is illustrated by several examples

A design-for-casting integrated approach based on rapid simulation and modulus criterion

This paper presents a new approach to the design of cast components and their associated tools. The current methodology is analysed through a case study and its main disadvantages underlined. Then, in order to overcome these identified drawbacks, a new approach is proposed. Knowing that this approach is mainly based on a rapid simulation of the process, basics of a simplified physical model of solidification are presented as well as an associated modulus criterion. Finally, technical matters for a software prototype regarding the implementation of this Rapid Simulation Approach (RSA) in a CAD environment are detailed

A novel haptic model and environment for maxillofacial surgical operation planning and manipulation

This paper presents a practical method and a new haptic model to support manipulations of bones and their segments during the planning of a surgical operation in a virtual environment using a haptic interface. To perform an effective dental surgery it is important to have all the operation related information of the patient available beforehand in order to plan the operation and avoid any complications. A haptic interface with a virtual and accurate patient model to support the planning of bone cuts is therefore critical, useful and necessary for the surgeons. The system proposed uses DICOM images taken from a digital tomography scanner and creates a mesh model of the filtered skull, from which the jaw bone can be isolated for further use. A novel solution for cutting the bones has been developed and it uses the haptic tool to determine and define the bone-cutting plane in the bone, and this new approach creates three new meshes of the original model. Using this approach the computational power is optimized and a real time feedback can be achieved during all bone manipulations. During the movement of the mesh cutting, a novel friction profile is predefined in the haptical system to simulate the force feedback feel of different densities in the bone

An isogeometric analysis for elliptic homogenization problems

A novel and efficient approach which is based on the framework of isogeometric analysis for elliptic homogenization problems is proposed. These problems possess highly oscillating coefficients leading to extremely high computational expenses while using traditional finite element methods. The isogeometric analysis heterogeneous multiscale method (IGA-HMM) investigated in this paper is regarded as an alternative approach to the standard Finite Element Heterogeneous Multiscale Method (FE-HMM) which is currently an effective framework to solve these problems. The method utilizes non-uniform rational B-splines (NURBS) in both macro and micro levels instead of standard Lagrange basis. Beside the ability to describe exactly the geometry, it tremendously facilitates high-order macroscopic/microscopic discretizations thanks to the flexibility of refinement and degree elevation with an arbitrary continuity level provided by NURBS basis functions. A priori error estimates of the discretization error coming from macro and micro meshes and optimal micro refinement strategies for macro/micro NURBS basis functions of arbitrary orders are derived. Numerical results show the excellent performance of the proposed method