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 forfabrication of these kinds of objects due to size limitations. The authors have developed a novel approach of layered manufacturing that is the most appropriate forphysical concept modelling. This paper presents the algorithms for geometrically-based modelling of the profile curve of the flexible blade tool. It also describes thealgorithm 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 thefront surfaces of the layers G2, quasi G1 continuity can be implemented at the transition from one layer to another. In the circumferential direction G0 continuityexists