Abstract We introduce a novel geometry‐processing pipeline to guide the fabrication of complex shapes from a single block of material using 4‐axis CNC milling machines. This setup extends classical 3‐axis CNC machining with an extra degree of freedom to rotate the object around a fixed axis. The first step of our pipeline identifies the rotation axis that maximizes the overall fabrication accuracy. Then we identify two height‐field regions at the rotation axis's extremes used to secure the block on the rotation tool. We segment the remaining portion of the mesh into a set of height‐fields whose principal directions are orthogonal to the rotation axis. The segmentation balances the approximation quality, the boundary smoothness, and the total number of patches. Additionally, the segmentation process takes into account the object's geometric features, as well as saliency information. The output is a set of meshes ready to be processed by off‐the‐shelf software for the 3‐axis tool‐path generation. We present several results to demonstrate the quality and efficiency of our approach to a range of inputs.

We propose a novel algorithm for decomposing general three-dimensional geometries into a small set of overlap-free height-field blocks , volumes enclosed by a flat base and a height-field surface defined with respect to this base. This decomposition is useful for fabrication methodologies such as 3-axis CNC milling, where a single milling pass can only carve a single height-field surface defined with respect to the machine tray but can also benefit other fabrication settings. Computing our desired decomposition requires solving a highly constrained discrete optimization problem, variants of which are known to be NP-hard. We effectively compute a high-quality decomposition by using a two-step process that leverages the unique characteristics of our setup. Specifically, we notice that if the height-field directions are constrained to the major axes, then we can always produce a valid decomposition starting from a suitable surface segmentation. Our method first produces a compact set of large, possibly overlapping, height-field blocks that jointly cover the model surface by recasting this discrete constrained optimization problem as an unconstrained optimization of a continuous function, which allows for an efficient solution. We then cast the computation of an overlap-free, final decomposition as an ordering problem on a graph and solve it via a combination of cycle elimination and topological sorting. The combined algorithm produces a compact set of height-field blocks that jointly describe the input model within a user given tolerance. We demonstrate our method on a range of inputs and showcase a number of real life models manufactured using our technique.

Abstract We propose a novel method for the automatic generation of structured hexahedral meshes of articulated 3D shapes. We recast the complex problem of generating the connectivity of a hexahedral mesh of a general shape into the simpler problem of generating the connectivity of a tubular structure derived from its curve‐skeleton. We also provide volumetric subdivision schemes to nicely adapt the topology of the mesh to the local thickness of tubes, while regularizing per‐element size. Our method is fast, one‐click, easy to reproduce, and it generates structured meshes that better align to the branching structure of the input shape if compared to previous methods for hexa mesh generation.