Prototyping Large-Sized Objects Using Freeform Thick Layers of Plastic Foam

Current Rapid Prototyping systems are primarily aimed at small-sized objects containing many shape details. In this paper a Rapid Prototyping technology is presented that is aimed at largesized objects having a complex, freeform outer shape. This new technology builds the model out ofthick layers, each having freeform outside faces. The paper will present: an overview of current methods to produce large prototypes, the basics of the new method, the technology used to produce the layers, the toolpath planning and finally the overall system design.