# US 10,372,109 B2 · Beam tool pathing for 3D compound contours using machining path surfaces to maintain a single solid representation of objects

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- Number: US 10,372,109 B2
- Document ID: US10372109B2
- Status: Granted
- Kind: B2
- Application number: 14/737,104
- Filed: 2015-06-11
- Published: 2015-12-17
- Granted: 2019-08-06
- Earliest claimed: 2014-06-16
- Assignees: Flow International Corporation
- Applicants: Flow International Corporation
- Inventors: Frank E. DeSimone; Vanessa A. Lind; Kenneth A. Mental; Alex M. Chillman
- Web page: https://patentgrep.com/patent/US10372109B2

## CPC

- G05B 19/4099: Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing
- B24C 3/00: Abrasive blasting machines or devices; Plants
- B26D 5/005: {Computer numerical control means}
- B26F 3/004: {by means of a fluid jet (methods for use of abrasive blasting for cutting B24C1/045; guns for abrasive fluid jets B24C5/02; perforating by non-mechanical means, e.g. by fluid jet B26F1/26)}
- G06F 30/00: Computer-aided design [CAD]
- G06F 30/10: Geometric CAD
- B24C 1/045: {for cutting (energy dissipating devices therefor B26F3/008)}
- G05B 2219/35051: Data exchange between cad systems, cad and cam
- G05B 2219/35097: Generation of cutter path, offset curve
- G05B 2219/35134: 3-D cad-cam
- G05B 2219/45036: Waterjet cutting
- G05B 2219/45041: Laser cutting
- G05B 2219/49012: Remove material by laser beam, air, water jet to form 3-D object
- G06F 2119/18: Manufacturability analysis or optimisation for manufacturability
- Y02P 90/02: Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
- G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G)
- B24C: ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B26D: CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING (for growing crops or plants A01D, A01G; for fodder or straw A01F; for bulk butter A01J; for dough A21C; slaughtering A22B; for tobacco, cigars or cigarettes A24; marking-out, perforating or making buttonholes A41H25/00; manufacturing footwear A43D; brushmaking A46D; surgery A61B; disintegrating, mincing or shredding in general B02C; cutting wire, making pins or nails B21F, B21G; of the kind used formetal B23; cutting by abrasive fluid jets B24C5/02; hand-held cutting tools B26B; perforating, cutting-out, stamping-out or punching, or severing by means other than cutting B26F; for wood B27; for stone B28D; working of plastics or substances in a plastic state B29; making boxes, cartons, envelopes or bags, of paper or similarly worked materials, e.g. metal foil, B31B; article or web delivery apparatus incorporating cutting or line-perforating devices B65H35/00; for leather or upholstery B68, C14B; for glass C03B; making matches C06F; for peat C10F; for sugar C13B45/00; for textile materials D06H; civil engineering, building, mining, see Section E; for light guides G02B6/25; cutting processed photographic material G03D15/04)
- B26F: PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING (marking-out, perforating or making buttonholes A41H25/00; shoemaking A43D; surgery A61B; punching metal B21D; drilling metal B23B; cutting of metal by applying heat locally, e.g. flame cutting, B23K; cutting by abrasive fluid jets B24C5/02; details common to machines for severing B26D; drilling wood B27C; drilling stone B28D; working of plastics or substances in a plastic state B29; making boxes, cartons, envelopes or bags, of paper or similarly worked materials, e.g. metal foil, B31B; of glass C03B; of leather C14B; of textile materials D06H; for light guides G02B6/25; of tickets G07B)
- G06F: ELECTRIC DIGITAL DATA PROCESSING (computer systems based on specific computational models G06N)
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

Computer based methods, systems, and techniques for planning and generating machining paths for a tool that manufactures a three dimensional object having beveled or “compound” contours from a workpiece. A computer aided design (CAD)/computer aided manufacturing (CAM) system creates intermediate machining path surfaces that extend based on a CAD solid model representing the geometry of the object to be manufactured. The intermediate machining path surfaces extend to a shape that simulates a cutting beam (e.g., a waterjet, a laser beam, etc.) of the tool. For a flat workpiece, the machining path surfaces may extend from a top surface of the workpiece, which is a tool beam entrance surface, to a bottom surface of the workpiece, which is a tool beam exit surface. An operator is able to visualize the cuts to be made and the actual finished object geometry, without requiring the creation of multiple CAD solid models.

## Claims

### Claim 1

A method of operation in a computer-aided manufacturing (CAM) system to define a machining orientation for a tool to manufacture a three dimensional physical object from a workpiece, the object having one or more machining faces which are to be machined by the tool during manufacturing, the CAM system includes a display, at least one processor, at least one nontransitory processor-readable medium communicatively coupled to the at least one processor and which stores at least one of instructions or data executable by the at least one processor, the method comprising:
obtaining a computer aided-design (CAD) solid model of the physical object to be manufactured from at least one nontransitory processor-readable medium;
identifying a first bounding area;
identifying a second bounding area;
identifying one or more non-spanning machining faces of the CAD solid model, each of the one or more non-spanning machining faces having a first edge relatively proximate to the first bounding area and a second edge relatively proximate to the second bounding area, at least one of the first edge and the second edge spaced apart from the first bounding area and the second bounding area, respectively, such that each of the one or more non-spanning machining faces do not span between the first bounding area and the second bounding area;
creating an extended machining path CAM surface model that defines a machining orientation for the tool, the extended machining path CAM surface model logically associated with one or more non-spanning machining faces of the CAD solid model in at least one nontransitory processor-readable medium, the extended machining path CAM surface model including one or more extended machining path CAM surfaces each a representation of a respective one of the non-spanning machining faces of the CAD solid model, the extended machining path CAM surface model including a first extended surface edge relatively proximate to the first bounding area defining a beam entrance contour and a second extended surface edge relatively proximate to the second bounding area defining a beam exit contour; and
autonomously extending the extended machining path CAM surface model, by the at least one processor, by at least one of,
autonomously extending the first extended surface edge of the extended machining path CAM surface model toward the first bounding area when the first extended surface edge is spaced apart from the first bounding area; or
autonomously extending the second extended surface edge of the extended machining path CAM surface model toward the second bounding area when the second extended surface edge is spaced apart from the second bounding area,
wherein autonomously extending the extended machining path CAM surface model includes creating one or more virtual or intermediate machining path CAM surface that extends from the CAD solid model of the physical object to be manufactured and which thus represents geometry that is absent from the physical object to be manufactured.

### Claim 2 (depends on 1)

The method of claim 1, further comprising:
generating motion instructions or data that specify movement for the tool according to the extended machining path CAM surface model; and
storing the motion instructions or data in the nontransitory processor-readable medium.

### Claim 3 (depends on 2)

The method of claim 2, further comprising:
receiving a selection of a positioning sequence for the motion instructions or data via a user interface of the CAM system; and
logically associating the positioning sequence with the motion instructions or data in at least one nontransitory processor-readable medium.

### Claim 4 (depends on 2)

The method of claim 2, further comprising:
sending the motion instructions or data to a controller associated with the tool.

### Claim 5 (depends on 2)

The method of claim 2, further comprising:
obtaining machining knowledge data stored in at least one nontransitory processor-readable medium, wherein at least a portion of the motion instructions or data are dependent upon the obtained machining knowledge data.

### Claim 6 (depends on 1)

The method of claim 1, wherein identifying a first bounding area includes logically associating a first bounding area with a first face of the CAD solid model in at least one nontransitory processor-readable medium, and identifying a second bounding area includes logically associating a second bounding area with a second face of the CAD solid model in at least one nontransitory processor-readable medium.

### Claim 7 (depends on 1)

The method of claim 1 wherein at least one of the first bounding area or the second bounding area has a planar shape.

### Claim 8 (depends on 1)

The method of claim 1 wherein at least one of the first bounding area or the second bounding area has a non-planar shape.

### Claim 9 (depends on 1)

The method of claim 1, further comprising:
causing the display of the CAM system to display the CAD solid model and the extended machining path CAM surface model.

### Claim 10 (depends on 1)

The method of claim 1, further comprising:
receiving a selection of the first face of the CAD solid model via a user interface of the CAD system; and
receiving a selection of the second face of the CAD solid model via a user interface of the CAD system.

### Claim 11 (depends on 1)

The method of claim 1 wherein extending the first extended surface edge of the extended machining path CAM surface model includes extending the first extended surface edge of the extended machining path CAM surface model to the first bounding area, and extending the second extended surface edge of the extended machining path CAM surface model includes extending the second extended surface edge of the extended machining path CAM surface model to the second bounding area.

### Claim 12 (depends on 1)

The method of claim 1 wherein extending the first extended surface edge of the extended machining path CAM surface model includes extending the first extended surface edge of the extended machining path CAM surface model a first distance toward the first bounding area, and extending the second extended surface edge of the extended machining path CAM surface model includes extending the second extended surface edge of the extended machining path CAM surface model a second distance toward the second bounding area.

### Claim 13 (depends on 1)

The method of claim 1, further comprising:
autonomously determining at least one of the one or more non-spanning machining faces of the CAD solid model has been modified; and
autonomously modifying, by the at least one processor, the extended machining path CAM surface model dependent on the modification to create a modified extended machining path CAM surface model.

### Claim 14 (depends on 13)

The method of claim 13, further comprising:
causing the display of the CAM system to display the modified CAD solid model and the modified extended machining path CAM surface model.

### Claim 15 (depends on 1)

The method of claim 1, further comprising:
identifying one or more spanning machining faces of the CAD solid model, each of the one or more spanning machining faces having a first edge at least a portion of which is adjacent the first bounding area and a second edge at least a portion of which is adjacent the second bounding area, such that each of the one or more non-spanning machining faces do not span between the first bounding area and the second bounding area; and
autonomously creating, by the at least one processor, a simplified machining path CAM surface model that defines a machining orientation for the tool, the simplified machining path CAM surface model logically associated with one or more spanning machining faces of the CAD solid model in at least one nontransitory processor-readable medium, the simplified machining path CAM surface model including one or more simplified machining path CAM surfaces, each simplified machining path CAM surface associated with a respective one of the spanning machining faces, the simplified machining path CAM surface model including a first simplified surface edge at least a portion of which is adjacent to the first bounding area defining a beam entrance contour and a second simplified surface edge at least a portion of which is adjacent to the second bounding area defining a beam exit contour.

### Claim 16 (depends on 15)

The method of claim 15, further comprising:
causing the display of the CAM system to display the CAD solid model, the extended machining path CAM surface model, and the simplified machining path CAM surface model.

### Claim 17 (depends on 15)

The method of claim 15 wherein extending the first extended surface edge of the extended machining path CAM surface model includes extending the first extended surface edge of the extended machining path CAM surface model to the first bounding area, and extending the second extended surface edge of the extended machining path CAM surface model includes extending the second extended surface edge of the extended machining path CAM surface model to the second bounding area.

### Claim 18 (depends on 15)

The method of claim 15 wherein extending the first extended surface edge of the extended machining path CAM surface model includes extending the first extended surface edge of the extended machining path CAM surface model a first distance toward the first bounding area, and extending the second extended surface edge of the extended machining path CAM surface model includes extending the second extended surface edge of the extended machining path CAM surface model a second distance toward the second bounding area.

### Claim 19 (depends on 15)

The method of claim 15, further comprising:
autonomously determining, by the at least one processor, at least one of the one or more machining faces of the CAD solid model has been modified; and
autonomously modifying, by the at least one processor, the extended machining path CAM surface model or the simplified machining path CAM surface model dependent on the modification to generate at least one of a modified extended machining path CAM surface model or a modified simplified machining path CAM surface model.

### Claim 20 (depends on 19)

The method of claim 19, further comprising:
causing the display of the CAM system to display the modified CAD solid model and the generated at least one modified extended machining path CAM surface model or modified simplified machining path CAM surface model.

### Claim 21 (depends on 15)

The method of claim 15 wherein the simplified machining path CAM surface model is logically associated with a chain of two or more spanning machining faces in at least one nontransitory processor-readable medium.

### Claim 22 (depends on 15)

The method of claim 15, further comprising:
autonomously combining, by the at least one processor, the extended machining path CAM surface model and the simplified machining path CAM surface model to create a combined machining path CAM surface model.

### Claim 23 (depends on 22)

The method of claim 22, further comprising:
causing the display of the CAM system to display the CAD solid model and the combined machining path CAM surface model.

### Claim 24 (depends on 15)

The method of claim 15, further comprising:
segmenting, by the at least one processor, the simplified machining path CAM surface model into object geometry vectors that define a machining orientation for the tool, each object geometry vector connecting an imaginary point on the first simplified surface edge of the simplified machining path CAM surface model to a corresponding imaginary point on the second simplified surface edge of the simplified machining path CAM surface model such that there is a one-to-one correspondence between the number of points on the first simplified surface edge of the simplified machining path CAM surface model and the second simplified surface edge of the simplified machining path CAM surface model.

### Claim 25 (depends on 15)

The method of claim 15, further comprising:
dividing, by the at least one processor, one of the simplified machining path CAM surfaces of the simplified machining path CAM surface model into a first simplified machining path CAM surface and a second simplified machining path CAM surface, each of the first simplified machining path CAM surface and a second simplified machining path CAM surface having a first edge and a second edge;
segmenting, by the at least one processor, the first simplified machining path CAM surface into object geometry vectors that define a machining orientation for the tool, each object geometry vector connecting an imaginary point on the first edge of the first simplified machining path CAM surface to a corresponding imaginary point on the second edge of the first simplified machining path CAM surface such that there is a one-to-one correspondence between the number of points on the first edge of the first simplified machining path CAM surface and the second edge of the first simplified machining path CAM surface; and
segmenting, by the at least one processor, the second simplified machining path CAM surface into object geometry vectors that define a machining orientation for the tool, each object geometry vector connecting an imaginary point on the first edge of the second simplified machining path CAM surface to a corresponding imaginary point on the second edge of the second simplified machining path CAM surface such that there is a one-to-one correspondence between the number of points on the first edge of the second simplified machining path CAM surface and the second edge of the second simplified machining path CAM surface.

### Claim 26 (depends on 1)

The method of claim 1, further comprising:
logically associating the extended machining path CAM surface model with a chain of two or more adjacent non-spanning machining faces in at least one nontransitory processor-readable medium.

### Claim 27 (depends on 1)

The method of claim 1 wherein creating an extended machining path CAM surface model logically associated with one or more non-spanning machining faces comprises copying the one or more non-spanning machining faces to create the extended machining path CAM surfaces.

### Claim 28 (depends on 1)

The method of claim 1, further comprising:
segmenting, by the at least one processor, the extended machining path CAM surface model into object geometry vectors that define a machining orientation for the tool, each object geometry vector connecting an imaginary point on the first extended surface edge of the extended machining path CAM surface model to a corresponding imaginary point on the second extended surface edge of the extended machining path CAM surface model such that there is a one-to-one correspondence between the number of points on the first extended surface edge of the extended machining path CAM surface model and the second extended surface edge of the extended machining path CAM surface model.

### Claim 29 (depends on 1)

The method of claim 1, further comprising:
dividing, by the at least one processor, one of the extended machining path CAM surfaces of the extended machining path CAM surface model into a first extended machining path CAM surface and a second extended machining path CAM surface, each of the first extended machining path CAM surface and a second extended machining path CAM surface having a first edge and a second edge;
segmenting, by the at least one processor, the first extended machining path CAM surface into object geometry vectors that define a machining orientation for the tool, each object geometry vector connecting an imaginary point on the first edge of the first extended machining path CAM surface to a corresponding imaginary point on the second edge of the first extended machining path CAM surface such that there is a one-to-one correspondence between the number of points on the first edge of the first extended machining path CAM surface and the second edge of the first extended machining path CAM surface; and
segmenting, by the at least one processor, the second extended machining path CAM surface into object geometry vectors that define a machining orientation for the tool, each object geometry vector connecting an imaginary point on the first edge of the second extended machining path CAM surface to a corresponding imaginary point on the second edge of the second extended machining path CAM surface such that there is a one-to-one correspondence between the number of points on the first edge of the second extended machining path CAM surface and the second edge of the second extended machining path CAM surface.

### Claim 30 (depends on 1)

The method of claim 1, further comprising:
creating, by the at least one processor, a lead-in machining path CAM surface that corresponds to a starting path of the tool, the lead-in machining path adjacent at least one other machining path CAM surface, the lead-in machining path CAM surface defined by a plurality object geometry vectors that define a machining orientation for the tool, wherein at least one of the plurality of object geometry vectors associated with a workpiece piercing location for the tool defines an orientation for the tool that positions a cutting beam of the tool perpendicular to a surface of the workpiece at the workpiece piercing position.

### Claim 31 (depends on 1)

The method of claim 1, further comprising:
creating, by the at least one processor, a lead-out machining path CAM surface that corresponds to a ending path of the tool, the lead-out machining path adjacent at least one other machining path CAM surface, the lead-out machining path CAM surface defined by a plurality object geometry vectors that define a machining orientation for the tool, wherein at least one of the plurality of object geometry vectors associated with an end location for the tool defines an orientation for the tool that positions a cutting beam of the tool perpendicular to a surface of the workpiece at the end location.

### Claim 32

A method of operation in a computer-aided manufacturing (CAM) system to define a machining orientation for a tool to manufacture a three dimensional physical object from a workpiece, the object having one or more machining faces which are to be machined by the tool during manufacturing, the CAM system includes a display, at least one processor, at least one nontransitory processor-readable medium communicatively coupled to the at least one processor and which stores at least one of instructions or data executable by the at least one processor, the method comprising:
obtaining a computer aided-design (CAD) solid model of the physical object to be manufactured from at least one nontransitory processor-readable medium;
identifying a first bounding area;
identifying a second bounding area;
identifying one or more machining faces of the CAD solid model to be machining by the tool, each of the one or more machining faces having a first edge and a second edge;
generating a machining path CAM surface model that defines a machining orientation for the tool, the machining path CAM surface model stored in at least one nontransitory processor-readable medium, and the machining path CAM surface model generated by,
autonomously, by the at least one processor, generating one or more initial machining path CAM surfaces, each of the initial machining path CAM surfaces logically associated with a respective one of the machining faces in at least one nontransitory processor-readable medium, each of the initial CAM machining faces having a first edge and a second edge corresponding to the first edge and the second edge, respectively, of the machining face with which each of the initial machining path CAM surfaces is logically associated; and
autonomously generating, by the at least one processor, one or more final machining path CAM surfaces of the machining path CAM surface model from the initial machining path CAM surfaces by, for each initial machining path CAM surface, extending the first edge toward the first bounding area when the first edge is spaced apart from the first bounding area, and extending the second edge toward the second bounding area when the second edge is spaced apart from the second bounding area, wherein the one or more final machining path CAM surfaces of the machining path CAM surface model are respective ones of one or more virtual or intermediate machining path CAM surface that extend from the CAD solid model of the physical object to be manufactured; and
causing the display of the CAM system to display the CAD solid model and the machining path CAM surface model.

### Claim 33 (depends on 32)

The method of claim 32, wherein identifying a first bounding area includes logically associating a first bounding area with a first face of the CAD solid model in at least one nontransitory processor-readable medium, and identifying a second bounding area includes logically associating a second bounding area with a second face of the CAD solid model in at least one nontransitory processor-readable medium.

### Claim 34 (depends on 32)

The method of claim 32, further comprising:
creating, by the at least one processor, a lead-in machining path CAM surface that corresponds to a starting path of the tool, the lead-in machining path adjacent at least one other machining path CAM surface, the lead-in machining path CAM surface defined by a plurality object geometry vectors that define a machining orientation for the tool, wherein at least one of the plurality of object geometry vectors associated with a workpiece piercing location for the tool defines an orientation for the tool that positions a cutting beam of the tool perpendicular to a surface of the workpiece at the workpiece piercing position.

### Claim 35 (depends on 32)

The method of claim 32, further comprising:
generating motion instructions or data, by the at least one processor, that specify movement for the tool according to the machining path CAM surface model.

### Claim 36 (depends on 35)

The method of claim 35, further comprising:
obtaining machining knowledge data stored in at least one nontransitory processor-readable medium, wherein at least a portion of the motion instructions or data are dependent upon the obtained machining knowledge data.

### Claim 37 (depends on 35)

The method of claim 35, further comprising:
storing the motion instructions or data in a nontransitory processor-readable medium.

### Claim 38 (depends on 35)

The method of claim 35, further comprising:
receiving a selection of a positioning sequence for the motion instructions or data via a user interface of the CAM system; and
logically associating the positioning sequence with the motion instructions or data in at least one nontransitory processor-readable medium.

### Claim 39 (depends on 32)

The method of claim 32, further comprising:
modifying the CAD solid model;
determining whether any of the machining faces of the CAD solid model are modified;
generating a modified machining path CAM surface model by, for each modified machining face,
autonomously generating, by the at least one processor, a modified initial machining path CAM surface logically associated in at least one nontransitory processor-readable medium with the modified machining face, the modified initial machining path CAM surface having a first edge and a second edge; and
autonomously generating, by the at least one processor, a modified final machining path CAM surface from the modified initial machining path CAM surface by extending the first edge toward the first bounding area when the first edge is spaced apart from the first bounding area, and extending the second edge toward the second bounding area when the second edge is spaced apart from the second bounding area; and
causing the display of the CAM system to display the modified CAD solid model and the modified machining path CAM surface model.

### Claim 40 (depends on 32)

The method of claim 32, further comprising:
dividing, by the at least one processor, one of the final CAM machining faces into a first portion and a second portion, each of the first portion and the second portion having a first edge and a second edge;
segmenting, by the at least one processor, the first portion into object geometry vectors that define a machining orientation for the tool, each object geometry vector connecting an imaginary point on the first edge of the first portion defining a jet entrance contour to a corresponding imaginary point on the second edge of the first portion defining a jet exit contour such that there is a one-to-one correspondence between the number of points on the top edge of the first portion and the bottom edge of the first portion; and
segmenting, by the at least one processor, the second portion into object geometry vectors that define the machining orientation for the tool, each object geometry vector connecting an imaginary point on the first edge of the second portion defining a jet entrance contour to a corresponding imaginary point on the second edge of the second portion defining a jet exit contour such that there is a one-to-one correspondence between the number of points on the top edge of the second portion and the bottom edge of the second portion.

### Claim 41 (depends on 32)

The method of claim 32 wherein extending the first edges of the initial CAM machining faces includes extending the first edges to the first bounding area, and extending the second edges of the initial CAM machining faces includes extending the second edges to the second bounding area.

### Claim 42

A processor-based system, comprising:
at least one processor; and
at least one nontransitory processor-readable medium, communicatively coupled to the at least one processor and which stores at least one of processor-executable instructions or data, wherein in use the at least one processor:
obtains a computer aided-design (CAD) solid model of the physical object to be manufactured from at least one nontransitory processor-readable medium;
identifies a first bounding area;
identifies a second bounding area;
identifies one or more non-spanning machining faces of the CAD solid model, each of the one or more non-spanning machining faces having a first edge relatively proximate to the first bounding area and a second edge relatively proximate to the second bounding area, at least one of the first edge and the second edge spaced apart from the first bounding area and the second bounding area, respectively, such that each of the one or more non-spanning machining faces do not span between the first bounding area and the second bounding area;
creates an extended machining path CAM surface model that defines a machining orientation for the tool, the extended machining path CAM surface model logically associated with one or more non-spanning machining faces of the CAD solid model in at least one nontransitory processor-readable medium, the extended machining path CAM surface model including one or more extended machining path CAM surfaces each a representation of a respective one of the non-spanning machining faces of the CAD solid model, the extended machining path CAM surface model including a first extended surface edge relatively proximate to the first bounding area defining a beam entrance contour and a second extended surface edge relatively proximate to the second bounding area defining a beam exit contour; and
autonomously extends the extended machining path CAM surface model, wherein the processor:
autonomously extends the first extended surface edge of the extended machining path CAM surface model toward the first bounding area when the first extended surface edge is spaced apart from the first bounding area; and
autonomously extends the second extended surface edge of the extended machining path CAM surface model toward the second bounding area when the second extended surface edge is spaced apart from the second bounding area,
wherein to autonomously extend the extended machining path CAM surface model the at least one processor creates one or more virtual or intermediate machining path CAM surface that extend from the CAD solid model of the physical object to be manufactured and which thus represents geometry that is absent from the physical object to be manufactured.

### Claim 43

A processor-based system, comprising:
at least one processor; and
at least one nontransitory processor-readable medium, communicatively coupled to the at least one processor and which stores at least one of processor-executable instructions or data, wherein in use the at least one processor:
obtains a computer aided-design (CAD) solid model of the physical object to be manufactured by a tool from at least one nontransitory processor-readable medium;
identifies a first bounding area;
identifies a second bounding area;
identifies one or more machining faces of the CAD solid model to be machining by the tool, each of the one or more machining faces having a first edge and a second edge;
generates a machining path CAM surface model that defines a machining orientation for the tool, the machining path CAM surface model stored in at least one nontransitory processor-readable medium, the processor executable instructions cause a processor to:
autonomously generate one or more initial machining path CAM surfaces, each of the initial machining path CAM surfaces logically associated with a respective one of the machining faces in at least one nontransitory processor-readable medium, each of the initial CAM machining faces having a first edge and a second edge corresponding to the first edge and the second edge, respectively, of the machining face with which each of the initial machining path CAM surfaces is logically associated;
autonomously generate one or more final machining path CAM surfaces of the machining path CAM surface model from the initial machining path CAM surfaces, the processor executable instructions cause a processor to, for each initial machining path CAM surface:
extend the first edge toward the first bounding area when the first edge is spaced apart from the first bounding area; and
extend the second edge toward the second bounding area when the second edge is spaced apart from the second bounding area, wherein the one or more final machining path CAM surface of the machining path CAM surface model are respective ones of one or more virtual or intermediate machining path CAM surface that extend from the CAD solid model of the physical object to be manufactured;
causes a display to display the CAD solid model and the machining path CAM surface model.