Morphing of watertight spline models using manufacturing data, inspection data, and product manufacturing information

A method, comprising:

• partially manufacturing a first object using a manufacturing process based at least in part on an as-designed model;
• while the first object is partially manufactured:
• measuring the first object to obtain a plurality of measurement points of the first object;
• constructing an as-inspected model of the first object based at least in part on the plurality of measurement points and the as-designed model, wherein the as-inspected model comprises a computer-aided inspection (CAI) model, and wherein constructing the as-inspected model comprises:
• determining a discrepancy between knot vectors of the as-inspected model and knot vectors of the as-designed model;
• and
• performing knot insertion on the knot vectors of the as-designed model to remove the determined discrepancy such that the knot vectors of the as-designed model and the knot vectors of the as-inspected model are the same;
• determining a warp function of the first object based on a difference between the as-designed model and the as-inspected model;
• modifying the as-designed model based on the warp function to compensate for one or more deviations identified by the warp function;
• modifying the manufacturing process based at least in part on the modified as-designed model;
• and
• completing the manufacturing of the first object based on the modified manufacturing process.

A non-transitory computer-readable memory medium comprising program instructions which, when executed by a processor, cause a computer to:

• provide instructions to manufacture a first object based at least in part on an as-designed model;
• provide instructions to measure the first object to obtain a plurality of measurement points of the first object;
• construct an as-inspected model of the first object based at least in part on the plurality of measurement points and the as-designed model, and wherein, in constructing the as-inspected model, the program instructions are executable to:
• determine a discrepancy between knot vectors of the as-inspected model and knot vectors of the as-designed model;
• and
• perform knot insertion on the knot vectors of the as-designed model to remove the determined discrepancy such that the knot vectors of the as-designed model and the knot vectors of the as-inspected model are the same;
• determine a warp function of the first object based on a difference between the as-designed model and the as-inspected model;
• modify the as-designed model based on the warp function to compensate for one or more deviations identified by the warp function;
• and
• provide instructions to manufacture a second object based at least in part on the modified as-designed model.