Computational analysis and design has become a fundamental part of product research, development, and manufacture in aerospace, automotive, and other industries. In general the success of the specific application depends heavily on the accuracy and consistency of the computational model used. The aim of this work is to reduce the time needed to prepare geometry for mesh generation. This will be accomplished by developing tools that semi-automatically repair discrete data. Providing a level of automation to the process of repairing large, complex problems in discrete data will significantly accelerate the grid generation process. The developed algorithms are meant to offer semi-automated solutions to complicated geometrical problems—specifically discrete mesh intersections and isolated boundaries. The intersection-repair strategy presented here focuses on repairing the intersection in-place as opposed to re-discretizing the intersecting geometries. Combining robust, efficient methods of detecting intersections and then repairing intersecting geometries in-place produces a significant improvement over techniques used in current literature. The result of this intersection process is a non-manifold, non-intersecting geometry that is free of duplicate and degenerate geometry. Results are presented showing the accuracy and consistency of the intersection repair tool. Isolated boundaries are a type of gap that current research does not address directly. They are defined by discrete boundary edges that are unable to be paired with nearby discrete boundary edges in order to fill the existing gap. In this research the method of repair seeks to fill the gap by extruding the isolated boundary along a defined vector so that it is topologically adjacent to a nearby surface. The outcome of the repair process is that the isolated boundaries no longer exist because the gap has been filled. Results are presented showing the precision of the edge projection and the advantage of edge splitting in the repair of isolated boundaries.

To handle broken 3D models can be a very time consuming problem. Several methods aiming for automatic mesh repair have been presented in the recent years. This thesis gives an extensive evaluation of automatic mesh repair algorithms, presents a mesh repair pipeline and describes an implemented automatic mesh repair algorithm. The presented pipeline for automatic mesh repair includes three main steps: octree generation, surface reconstruction and ray casting. Ray casting is for removal of hidden objects. The pipeline also includes a pre processing step for removal of intersecting triangles and a post processing step for error detection. The implemented algorithm presented in this thesis is a volumetric method for mesh repair. It generates an octree in which data from the input model is saved. Before creation of the output, the octree data will be patched to remove inconsistencies. The surface reconstruction is done with a method called Manifold Dual Contouring. First new vertices are created from the information saved in the octree. Then there is a possibility to cluster vertices together for decimation of the output. Thanks to a special Manifold criterion, the output is guaranteedto be manifold. Furthermore the output will have sharp and clear edges and corners thanks to the use of Singular Value Decomposition during determination of the positions of the new vertices.

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