This paper addresses the challenge of efficiently abstracting mid-surfaces from complex variable thin-walled models, a critical task in computer-aided design (CAD) and finite element analysis (FEA) for simplifying thin-walled structures. Traditional methods often require manual specification of pairing faces, which can be time-consuming and error-prone. Alternatively, automatic face pairing methods fail to meet the actual needs of variable thin-walled models, resulting in the accumulation of topological errors. Additionally, existing algorithms struggle to extract mid-surfaces from models with varying wall thickness or produce mid-surfaces with poor accuracy, leading to geometric errors. Furthermore, the computational efficiency of these methods is often inadequate for large-scale models. To overcome these challenges, we propose an automated face-pairing mechanism that eliminates the need for manual intervention, enhancing the algorithm’s robustness and enabling it to handle cases that the commercial CAD modeling engine, Parasolid, cannot process. Our approach accurately processes variable thin-walled models, with results closely aligning with the ground truth, as demonstrated by the provided error distribution tables. Moreover, our algorithm achieves a times improvement in efficiency than previous methods over the geometry extraction stage and supports multi-threaded acceleration, significantly reducing computation time. Experimental results demonstrate that our algorithm surpasses existing methods in both accuracy and efficiency, offering a promising solution for mid-surface extraction in complex, variable thin-walled models.
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