Patent Document ID: 4697240
Application ID: 06738604
Patent Flag: 1

Claim One:
1. A method for constructing a three-dimensional master model using computer assisted design and numerical control machine tool cutter techniques, said method comprising the steps of digitally processing relatively low density surface data to obtain male template contour lines; producing a set of male templates from said contour lines, the edges of said templates being offset a first dimension below a surface on an axis normal thereto; assembling said templates into an egg crate type structure comprising spaced templates with edges generally defining a desired master model but offset below a final desired surface on an axis normal thereto; filling in spaces between said templates edges to provide a substantially continuous surface; providing a layer of millable material on said surface, said layer being of a thickness greater than said first dimension to thereby provide a rough model having a surface offset above said final desired surface on an axis normal thereto; sweetening said relatively low density surface data to provide relatively higher density surface data and then N/C milling said surface of said rough model to a desired surface using said relatively higher density surface data.