Patent ID: 8155778

Claim:
A method of fabricating insulated ductwork comprising: generating, using a computer comprising at least one software algorithm and responsive to user input, a set of desired substrate characteristics for said insulated ductwork, including selecting a multi-layered insulation substrate; generating, using the computer and responsive to user input, a set of desired process characteristics, including a ductwork fabrication sequence; transmitting the set of desired process characteristics, including the ductwork fabrication sequence, from the computer to a computer numerical controlled machine; controlling a first angled cone-shaped cutting tool using the computer numerical controlled machine to cut the multi-layered insulation substrate to a first depth responsive to the ductwork fabrication sequence; controlling a second periphery cutting tool using the computer numerical controlled machine to cut the multi-layered insulation substrate to a second depth to form a first portion and a second portion having angled edges, also responsive to the ductwork fabrication sequence; and joining the angled edge of the first portion and the angled edge of the second portion to form a ductwork edge portion; wherein the multi-layered insulation substrate comprises a glass fiber layer and an aluminum foil layer, and the aluminum foil layer remains uncut and forms a continuous barrier surface when folded.