DSCarver: decompose-and-spiral-carve for subtractive manufacturing.

We present an automatic algorithm for subtractive manufacturing of freeform 3D objects using high-speed machining (HSM) via CNC. A CNC machine operates a cylindrical cutter to carve off material from a 3D shape stock, following a tool path, to "expose" the target object. Our method decomposes the input object's surface into a small number of patches each of which is fully accessible and machinable by the CNC machine, in continuous fashion, under a fixed cutter-object setup configuration. This is achieved by covering the input surface with a minimum number of accessible regions and then extracting a set of machinable patches from each accessible region. For each patch obtained, we compute a continuous, space-filling, and iso-scallop tool path which conforms to the patch boundary, enabling efficient carving with high-quality surface finishing. The tool path is generated in the form of connected Fermat spirals, which have been generalized from a 2D fill pattern for layered manufacturing to work for curved surfaces. Furthermore, we develop a novel method to control the spacing of Fermat spirals based on directional surface curvature and adapt the heat method to obtain iso-scallop carving. We demonstrate automatic generation of accessible and machinable surface decompositions and iso-scallop Fermat spiral carving paths for freeform 3D objects. Comparisons are made to tool paths generated by commercial software in terms of real machining time and surface quality.