Generating assembly features onto split solid models

A large model can be split into smaller components where by assembly features can be created and attached onto the components so that they can be reassembled to form the original model. The assembly features may function as positioning or interlocking purposes depending on the mating requirement. This paper describes a method for creating assembly features onto the solid components automatically. The main idea of the method is to construct spatial rectangular assembly cells inside the original model. This is done by ray tracing the tool surface that is used to split the model, provided that there is no undercut on the split surface along the assembly direction. The spatial cells represent solid regions in which assembly features can be attached. Different kinds of assembly features can be mapped to the spatial cells, which are then attached to the split components. The split surface can be planar, quadrics or higher order freeform surfaces, thus allowing a high degree of flexibility in creating the assembly feature shapes.