How do you handle complex or irregular surface models when converting them to solid models?

1 Choose the right software

Not all CAD/CAM software can handle surface models and solid models equally well. Some are more specialized in one or the other, or have different tools and features for conversion. For example, some software can automatically stitch surfaces into solids, while others require manual trimming and joining. Some software can handle complex surface intersections, while others may create gaps or errors. Therefore, you should choose the software that best suits your needs and capabilities, and be familiar with its limitations and advantages.

2 Prepare the surface model

Before converting a surface model to a solid model, you should check and prepare the surface model for any issues that may affect the conversion. For example, you should ensure that the surface model is closed, meaning that there are no holes or gaps in the surface boundary. You should also repair any surface defects, such as duplicate faces, overlapping edges, or inverted normals. You can use various tools and commands in your software to inspect, analyze, and fix the surface model, such as checking for continuity, curvature, or interference.

3 Apply the conversion method

Depending on your software and desired outcome, you can use various methods to convert a surface model to a solid model. Stitching involves joining adjacent or overlapping surfaces into one, and filling any gaps or holes with additional surfaces. Thicken adds thickness to a surface model by extruding it along a normal direction, while Solidify creates a solid model from a surface model by filling the interior volume with material. All of these methods result in a solid model with the same shape and size as the surface model, but with different characteristics.

4 Verify the solid model

After converting a surface model to a solid model, you should verify that the solid model is accurate and error-free. You can use various tools and commands in your software to check and validate the solid model, such as measuring dimensions, volumes, or masses, comparing the original and converted models, or performing analysis or simulation. You should also review and edit the solid model if needed, such as adding or modifying features, parameters, or constraints.

5 Export the solid model

Finally, you should export the solid model to a suitable format for your intended use. Depending on your software and purpose, you can choose from different file formats that can preserve the geometry, properties, and features of the solid model. For example, STEP is a standard format for exchanging CAD data between different software and can store both surface and solid models, as well as their attributes and relationships. STL is a popular format for 3D printing and rapid prototyping that can store only surface models but can represent complex shapes with high resolution. IGES is an older format for exchanging CAD data between different software which can store both surface and solid models, but may lose some information or quality during conversion.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?