Flexible mesh morphing in sustainable design using data mining and mesh subdivision

Abstract As a representative method of model surface, triangular mesh, which commonly has the stereo lithography (STL) format, has recently been widely applied in the CAD/CAE/CAM field, due to its superior robustness and high efficiency in tool-path generation. 3D product model optimization is of great importance for improvement of function, reduction of production material, and improvement of the company’s competition. Based on the circumstance of 3D modeling, simulation and optimization technologies, developing a more sustainable product and process become possible. However, there are many situations of the morphing, which are hard to be uniformed. Thus, developing a commonly used data-driven morphing method is difficult. In this paper, morphing situations are categorized into two classes, the algebraic morphing and the free-form morphing. Algebraic morphing patterns are developed, which can be adopted independently or combined together to complete complicated morphing operations. In the free-form morphing, control points are obtained by data mining, and then mesh subdivision is applied to refine surfaces smoothly. The proposed morphing method is applied to a truss core panel and a human head model, clarifying the robust function and high efficiency of the method proposed in this study to deal with complex 3D product model sustainable optimization.