Non-uniform deformation of an STL model satisfying error criteria

In this research, a method is presented for generating a deformed model satisfying given error criteria from an STL model in a triangular-mesh representation suitable for rapid prototyping (RP) processes. A deformed model is a non-uniformly modified shape from a base STL model. In developing a family product with various sizes such as a shoe, sometimes prototypes for all sizes should be made using an RP machine. Although an STL model is generated from a solid model, it is well known that creating a non-uniformly modified solid model from a base solid model is very difficult. Generally there are some gaps between surfaces after modification, and stitching the gaps is very difficult. To solve this problem, the authors explored the possibility of generating a deformed STL model directly from a base STL model. This research includes a data structure for modifying the STL model, checking the error of a modified edge compared with the exact non-uniformly scaled curve, checking the error of a modified facet compared with the exact non-uniformly scaled surface, and splitting a facet with an error greater than the allowable tolerance. Using the results of this research, the difficult work of creating solid models to build non-uniformly deformed STL models could be avoided.