The injection mold is one of the most important elements for the part precision of this important mass production process. The thermal mold design is realized by cooling channels around the cavity and poses as a decisive factor for the part quality. Thus, the objective but specific design of the cooling channel layout is crucial for a reproducible part with high-dimensional accuracy in production. Consequently, knowledge-based and automated methods are used to create the optimal heat management in the mold. One of these methods is the inverse thermal mold design, which uses a specific calculation space. The geometric boundary conditions of the optimization algorithm influence the resulting thermal balance within the mold. As the calculation area in the form of an offset around the molded part is one of these boundary conditions, its influence on the optimization result is determined. The thermal optimizations show a dependency on different offset shapes due to the offset thickness and coalescence of concave geometries. An algorithm is developed to generate an offset for this thermal mold design methodology considering the identified influences. Hence, a reproducible and adaptive offset is generated automatically for a complex geometry, and the quality function result improves by 43% in this example.
Boolean operators are an essential tool in a wide range of geometry processing and CAD/CAM tasks. We present a novel method, EMBER, to compute Boolean operations on polygon meshes which is exact, reliable, and highly performant at the same time. Exactness is guaranteed by using a plane-based representation for the input meshes along with recently introduced homogeneous integer coordinates. Reliability and robustness emerge from a formulation of the algorithm via generalized winding numbers and mesh arrangements. High performance is achieved by avoiding the (pre-)construction of a global acceleration structure. Instead, our algorithm performs an adaptive recursive subdivision of the scene's bounding box while generating and tracking all required data on the fly. By leveraging a number of early-out termination criteria, we can avoid the generation and inspection of regions that do not contribute to the output. With a careful implementation and a work-stealing multi-threading architecture, we are able to compute Boolean operations between meshes with millions of triangles at interactive rates. We run an extensive evaluation on the Thingi10K dataset to demonstrate that our method outperforms state-of-the-art algorithms, even inexact ones like QuickCSG, by orders of magnitude.
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