Geodesic-based iso-scallop tool path planning for complex free-form surfaces with uncut region elimination

Geodesic-based iso-scallop tool path planning for complex free-form surfaces with uncut region elimination | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Geodesic-based iso-scallop tool path planning for complex free-form surfaces with uncut region elimination Zicheng Hong, Guodong Hu, Xiaobo Chen, Juntong Xi This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7161211/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 27 Jan, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Complex free-form surface machining plays a critical role in biomedical and customized manufacturing, where high manufacturing accuracy is essential for ensuring functional and anatomical performance. Traditional iso-scallop tool path planning methods control scallop height to enhance surface quality. However, these methods often struggle to balance machining efficiency and precision, resulting in redundant tool paths or uncut regions, particularly when applied to triangular mesh models.To address these limitations, this study introduces a geodesic-based framework that constructs curvature-adaptive contours as tool paths using the heat flow method. A novel strategy based on direction field singularities and a Minimal Envelope Line is developed to accurately detect uncut regions, which are subsequently resolved through globally optimized Clean-Paths.Experimental results on synthetic and anatomical surfaces confirm the effectiveness of the method in minimizing redundant paths, eliminating residual uncut regions, and maintaining scallop height within prescribed tolerances. The approach also demonstrates reduced overall tool path length and computational time compared to benchmark methods, validating both its precision and efficiency. By integrating geodesic-based tool path planning, critical points informed uncut detection, and global Clean-Path optimization, this work presents a geometry-aware strategy for iso-scallop machining of complex mesh surfaces, offering improved scalability, accuracy, and reliability in mesh-based CNC applications. Triangular mesh Iso-scallop tool path generation Uncut region elimination Heat-geodesic field Direction field analysis Full Text Cite Share Download PDF Status: Published Journal Publication published 27 Jan, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 09 Nov, 2025 Reviewers agreed at journal 27 Aug, 2025 Reviewers invited by journal 27 Aug, 2025 Editor assigned by journal 22 Jul, 2025 First submitted to journal 21 Jul, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7161211","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":506607317,"identity":"ca6c2a52-736a-4cb0-8aa6-a2b902f4990a","order_by":0,"name":"Zicheng Hong","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Zicheng","middleName":"","lastName":"Hong","suffix":""},{"id":506607318,"identity":"ecdfda6c-340c-42fe-a25c-bec8d164caca","order_by":1,"name":"Guodong Hu","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Guodong","middleName":"","lastName":"Hu","suffix":""},{"id":506607319,"identity":"0524fdc9-0aa9-424b-be29-3e4bb6da9bf8","order_by":2,"name":"Xiaobo Chen","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Xiaobo","middleName":"","lastName":"Chen","suffix":""},{"id":506607320,"identity":"7134f027-fda4-4d4f-8fd4-c876c3e203b6","order_by":3,"name":"Juntong Xi","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAwElEQVRIiWNgGAWjYBACxgYGhgMfGNjAHAnitLQxMBycwcAmQbwWkPnMPFDVxGlhnt9jeNjmD1+dwQHmg7d5GOzyiHAYW8Lh3DY2CYMDbMnWPAzJxURoYT5wOLcBpIXHTJqH4UBiA2EtjA2HLf6AtPB/I1YL0BYGNrAtbMRqSUs42NvGJjnzMJux5RyDZMJaDJvPGH/48ecYP9/x5oc33lTYEaEFouIYMLhBtAEh9UAgD6FqiFA6CkbBKBgFIxYAAPrrN1mcWawIAAAAAElFTkSuQmCC","orcid":"","institution":"Computer Integrated Manufacturing","correspondingAuthor":true,"prefix":"","firstName":"Juntong","middleName":"","lastName":"Xi","suffix":""}],"badges":[],"createdAt":"2025-07-19 01:56:39","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-7161211/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-7161211/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s00170-025-17358-x","type":"published","date":"2026-01-27T15:58:12+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":101690777,"identity":"f367b30d-57d7-48e4-89dd-7ade8556e159","added_by":"auto","created_at":"2026-02-02 16:08:31","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":11788607,"visible":true,"origin":"","legend":"","description":"","filename":"JAMTD2504103reviewer.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7161211/v1_covered_d8188279-cdfb-4248-acad-18353adbe726.pdf"}],"financialInterests":"","formattedTitle":"Geodesic-based iso-scallop tool path planning for complex free-form surfaces with uncut region elimination","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":true,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Triangular mesh, Iso-scallop tool path generation, Uncut region elimination, Heat-geodesic field, Direction field analysis","lastPublishedDoi":"10.21203/rs.3.rs-7161211/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7161211/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003e Complex free-form surface machining plays a critical role in biomedical and customized manufacturing, where high manufacturing accuracy is essential for ensuring functional and anatomical performance. Traditional iso-scallop tool path planning methods control scallop height to enhance surface quality. However, these methods often struggle to balance machining efficiency and precision, resulting in redundant tool paths or uncut regions, particularly when applied to triangular mesh models.To address these limitations, this study introduces a geodesic-based framework that constructs curvature-adaptive contours as tool paths using the heat flow method. A novel strategy based on direction field singularities and a Minimal Envelope Line is developed to accurately detect uncut regions, which are subsequently resolved through globally optimized Clean-Paths.Experimental results on synthetic and anatomical surfaces confirm the effectiveness of the method in minimizing redundant paths, eliminating residual uncut regions, and maintaining scallop height within prescribed tolerances. 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