A novel method for early formal developments using computer aided design and rapid prototyping technology

The paper describes a novel method for updating computer aided design (CAD) models with information taken from physical models in the early stages of design. The new approach is an image mapping based method in which an initial CAD model is transferred to a soft rapid prototype model (RPM) made by a three-dimensional printer and sculpted in order to carry out formal developments. The RPM has a built-in contrasting three-dimensional grid composed of parallel orthogonal planes, and the initial CAD model is represented by cross-section curves corresponding to the RPM grid. The initial CAD geometry is then updated from images of the developed RPM by matching the differences between the initial CAD model and the modified RPM, making use of identical perspective transformations and viewpoints for the initial CAD model and an RPM image. Examples studied varied from a small depression on a cube face to general freeform surfaces. Compared with typical reverse engineering (RE) processes, the present approach is simpler and more direct. It is not necessary to use three-dimensional scanning or coordinate measuring devices for updating existing initial CAD models with data obtained from physical models