Boolean Operation for CAD Models Using a Hybrid Representation

Boolean operations for Boundary Representation (B-Rep) models are among the most commonly used functions in Computer Aided Design (CAD) systems. They are also one of the most delicate soft modules, with challenges arising from complex algorithmic flows and efficiency and accuracy issues, especially in extreme cases. Common issues encountered in processing complex models include low efficiency, missing results, and non-watertightness. In this paper, we propose a novel algorithm for efficient and accurate Boolean operations on B-Rep models. This is achieved by establishing a bijective mapping between B-Rep models and the corresponding triangle meshes with controllable approximation error, thus mapping B-Rep Boolean operations to mesh Boolean operations. By using conservative intersection detection on the mesh to locate all surface intersection curves and carefully handling degeneration and topology errors, we ensure that the results are consistently watertight and correct. We demonstrate the superior efficiency of the proposed method using the open-source geometry engine OCCT, the commercial engine ACIS, and the commercial software Rhino as benchmarks.