Tool profile and tool path calculation for free-form thick-layered fabrication

In several application fields, large sized, free-form objects of various soft materials are widely used. Available layered prototyping technologies cannot be applied for fabrication of these kinds of objects due to size limitations. The authors have developed a novel approach of layered manufacturing that is the most appropriate for physical concept modeling. This paper presents the algorithms for geometrically-based modeling of the profile curve of the flexible blade tool. It also describes the algorithm for direct slicing of the CAD model. The second part of the paper deals with the algorithms for slicing, tool positioning and tool path calculation. On the front surfaces of the layers G(2), quasi G(1) continuity can be implemented at the transition from one layer to another. In the circumferential direction G(0) continuity exists. (C) 1999 Elsevier Science Ltd. All rights reserved.