Robust and Automated Tetrahedral Mesh Generation From Imperfect Computer‐Aided Design Models for Computational Electromagnetics

Finite element analysis (FEA) is a fundamental technique in computational electromagnetics (CEM), and its accuracy and stability largely depend on the quality and geometric consistency of the mesh. As modern electronic systems increasingly involve complex computer‐aided design (CAD) geometries, conventional meshing methods may fail when the input models contain defects such as self‐intersections or overlaps. This paper presents an automated and numerically stable tetrahedral mesh generation framework that can produce solver‐ready meshes directly from imperfect CAD models. The framework combines Wild Tetrahedralization for fault‐tolerant boundary recovery under floating‐point arithmetic, a background‐tree‐based geometry–mesh mapping for consistent association between mesh elements and CAD entities, and a physics‐aware refinement process that couples wavelength and port constraints with adaptive optimization. Experiments on a range of representative electronic models show that the proposed approach reliably generates high‐quality, non‐degenerate volumetric meshes and maintains stability even for geometries with considerable imperfections.