@gustojunk
It took me about 8/10 minutes on my 10-year-old work PC.
What really surprised me about the Polyspline command is that it can convert very dense quad meshes like this one into NURBS, and it does a remarkably good job.
That said, I still prefer Rhino’s ToNURBS “Packed” method. In most cases, especially if you’re going to build a mold from the model, having thousands of tiny quadrangular NURBS patches is more of a disadvantage than an advantage. Managing that many surfaces quickly becomes heavy and visually cluttered unless you have a very powerful workstation.
Over the last few weeks at work I’ve had to convert several meshes to NURBS, and Polyspline has been very useful because, in some cases, Rhino would keep processing indefinitely or struggle with the conversion, while Polyspline converted those dense meshes to NURBS in roughly 5–10 minutes.
Thinking about Polyspline and Rhino’s ToNURBS, I have another consideration. Let’s say I want to preserve the quad-based structure, but I also want something equivalent to Rhino’s Packed option. It would be useful to have a sort of “Quad Packed” mode where, for example, an area containing 20 quad faces could be merged into 10 larger quad-based patches by intelligently absorbing neighboring regions, similar to what Packed does. This would significantly reduce visual clutter and file complexity while still preserving the quad layout.
Something similar to the ReduceMesh concept could work: a percentage reduction slider or a target face count. That would provide a nice balance between maintaining a quad structure and keeping the resulting NURBS model manageable.
For example, in this case I created an internal offset of the mesh by 0.8 mm, then converted the mesh into a quad mesh. To speed up the process, since Rhino’s ToNURBS was taking too long, I used Polyspline for the conversion.
This converted portion is useful for some of my milling strategies because, as @osuire mentioned, “Some milling strategies are exclusive to surface geometry.”
@JKolodner @cdordoni So the external geometry that will actually be machined remains a mesh, while I use an internal offset of that same mesh as a guide, first converted into a quad mesh and then into NURBS. This allows me to take advantage of machining strategies that require surface geometry without having to convert the entire model to NURBS.
