Patent ID: 7379787

Claim:
A method for forming a laminated tool from a sheet material having tolerance variances comprising: modeling a laminated tool using software; modeling a plurality of generally planar sectional members of the laminated tool to collectively provide the laminated tool; rotating alternating sectional members of the tool approximately 180 degrees about an axis generally parallel to the planar sectional members within the software, thereby providing a plurality of rotated sectional members and a remaining plurality of unrotated sectional members; using said plurality of software-modeled rotated sectional members to create a first plurality of physical sectional members from a generally planar sheet material having tolerance variances; using said plurality of software-modeled unrotated sectional members to create a second plurality of physical sectional members from a generally planar sheet material having tolerance variances; rotating said first plurality of physical sectional members approximately 180 degrees about an axis generally parallel to the planar physical sectional members, thereby reducing additive tolerance variances; and coupling said first plurality of physical sectional members to said second plurality of physical sectional members, thereby creating said laminated tool.