Free-form thick layer object manufacturing technology for large-sized physical models

Large-sized free-form objects of different materials are widely used in various industrial applications. Currently, layered rapid prototyping technologies are not suitable for the fabrication of this kind of objects, due to the necessity of a large number of layers and the limitations in size. This paper reports a novel approach of layered manufacturing that is more appropriate for the fabrication of these large objects. A method of thick-layered object manufacturing is presented, which is based on a higher order approximation of the shape and application of a flexible curved cutting tool. thod allows the production of physical prototypes, which need little or no finishing. In order to meet the designerʹs intend, as closely as possible, some feasible system characteristics are introduced. The process is ordered in a sequential way and provides a highly automated process. A hierarchical decomposition of the CAD geometry takes place into components, segments, layers and sectors, based on morphological analysis. This method enables the manufacturing and the re-assembly of the parts to produce the physical prototypes without affecting the requested functionality. Due to the possibility of obtaining multiple solutions in the physical model, much attention must be paid to the efficiency of the process.