Comparative Analysis and Experimental Verification of the Computed Shape of a Flexible Blade Tool for Ff-tlom

A novel technology introduced by the authors as free form thick layered object manufacturing (FF-TLOM), aims specifically at the field of large sized free form objects. The system under development will be able to produce large editable free form prototypes that can be used in the conceptual phase of the design. The considered technology of cutting polystyrene slabs using a heated flexible cutting blade is developed and currently being optimized. Work has been done already on the control of the actual cutting process by elaborating experiments on a range of influential process parameters. A further step is the accurate control of the shape of the flexible cutting device. Theories are known for the calculation of the shape of a flexible bar under specific constraints. The known theories and algorithms must be validated by experimental verification. The paper describes explorative experiments with the aim to develop a method that can be used for this experimental verification. Two implemented algorithms for the calculation of blade shapes are described as well as a number of calculations that were performed using these algorithms. The calculated results are being compared to each other and to real world experiments in order to determine their validity. The results of the experiments indicate that both of the algorithms could be applied for our shape calculations, however more experiments and analysis have to be performed on the subject. It becomes clear that small deviations in the applied constraints can, under specific circumstances, have large effects on the generated blade shapes.