The paper outlines a new approach to CADCAM compatible with the needs
and skills of small toolmaking companies. The approach is directed pri
marily to the production of complex shaped tooling for EDM, and embrac
es the whole process from 2-D part drawings to machined graphite elect
rodes. The key is to reject the notion that the CAD surface model shou
ld be absolutely correct and to establish a practical balance of toler
ances between the design and manufacturing phases. This leads to a new
strategy for surface modelling which is virtually automatic and a new
method for surface machining based on cross-sectional curves.