TY - JOUR AB - A new surface error calculation method for layered manufacturing processes is proposed in this paper. The developed method is used to generate the layers by adaptively varying the thickness of the layers based on the surface approximation errors. Traditionally, the surface errors are calculated using local approximation techniques. In this paper, the surface approximation errors are calculated more accurately by marching through the surface points and determining the distances between layers and the surface points. Using the calculated distances, the adaptive layers are generated for both traditional two‐dimensional layer and ruled‐layer approximation methods. It has been shown that layered manufacturing (rapid prototyping) processes can achieve better accuracy and efficiency using the proposed surface error calculation and the adaptive ruled layer approximation methods. Computer implementation and illustrative examples are also presented in this paper. VL - 10 IS - 5 SN - 1355-2546 DO - 10.1108/13552540410562304 UR - https://doi.org/10.1108/13552540410562304 AU - Koc Bahattin PY - 2004 Y1 - 2004/01/01 TI - Adaptive layer approximation of free‐form models using marching point surface error calculation for rapid prototyping T2 - Rapid Prototyping Journal PB - Emerald Group Publishing Limited SP - 270 EP - 280 Y2 - 2024/05/01 ER -