Abstract: A system and method for toolpath creation is provided. The method includes exporting CAD defined 3-D geometry to a slicing module; slicing the 3-D geometry creating a set of 2-D patterns representing the 3-D geometry; generating vector code from the set of 2-D patterns; and translating the vector code to machine code.

Abstract: In accordance with the present invention a method for the direct manufacture of aerospace duct elements is provided comprising executing a single build run on a build chamber using direct fabrication technology to generate at least one duct section. The at least one duct section is generated by forming a plurality of partial cylinder duct segments orientated within the build chamber in a nested arrangement during the single build run, and assembling at least two of the partial cylinder duct segments to form the duct section. During the single build run a plurality of stiffening protrusions are formed on each of the partial cylinder duct segments during to improve duct rigidity.

Abstract: In accordance with the present invention a method for the direct manufacture of aerospace duct elements is provided comprising executing a single build run on a build chamber using direct fabrication technology to generate at least one duct section. The at least one duct section is generated by forming a plurality of partial cylinder duct segments orientated within the build chamber in a nested arrangement during the single build run, and assembling at least two of the partial cylinder duct segments to form the duct section. The duct section has a duct cross-sectional profile larger than a build chamber profile.