This work documents a new method for rapid and robust Cartesian mesh g
eneration for component-based geometry. The new algorithm adopts a nov
el strategy that first intersects the components to extract the wetted
surface before proceeding with volume mesh generation in a second pha
se. The intersection scheme is based on a robust geometry engine that
uses adaptive precision arithmetic and automatically and consistently
handles geometric degeneracies with an algorithmic tie-breaking routin
e. The intersection procedure has worst-case computational complexity
of O(N log N) and is demonstrated on test cases with up to 121 overlap
ping and intersecting components, including a variety of geometric deg
eneracies. The volume mesh generation takes the intersected surface tr
iangulation as input and generates the mesh through cell division of a
n initially uniform coarse grid. In refining hexagonal cells to resolv
e the geometry, the new approach preserves the ability to directionall
y divide cells that are well aligned with local geometry. The mesh gen
eration scheme has linear asymptotic complexity with memory requiremen
ts that total approximately 14-17 words/cell. The mesh generation spee
d is approximately 10(6) cells/minute on a typical engineering worksta
tion.