Heterogeneous object modeling through direct face neighborhood alteration

Two recent advances—the use of functionally gradient materials in parts and layered manufacturing technology— have brought to the forefront the need for design and fabrication methodologies for heterogeneous objects. However, current solid modeling systems, a core component of computer-aided design and fabrication tools, are typically purely geometry based, and only after the modeling of product geometry, can a part’s non-geometric attributes such as material composition be modeled. This sequential order of modeling leads to unnecessary operations and oversegmented 3D regions during heterogeneous object modeling processes. To enable an efficient design of heterogeneous objects, we propose a novel method, direct face neighborhood operation. This approach combines the geometry and material decisions into a common computational framework as opposed to separate and sequential operations in existing modeling systems. We present theories and algorithms for direction face neighborhood alteration, which enables direct alteration of face neighborhood before 3D regions are formed. This alteration is based on set membership classification (SMC) and region material semantics. The SMC is computationally enhanced by the usage of topological characteristics of heterogeneous objects. After the SMC, boundary evaluation is performed according to the altered face neighborhood. In comparison with other solid modeling methods, the direct face neighborhood alteration method is computationally effective, allows direct B-Rep operations, and is efficient for persistent region naming. A prototype system has been implemented to validate the method and some examples are presented. r 2003 Elsevier Ltd. All rights reserved.