Swarfing a not so complex, complex surface with custom tool.

[huskermcdoogle]

I have a surface that we generate on some semi regularly repeating parts.  Its free form in nature, but doesn't have to be exact.  I was doing some initial figuring and think this is pretty possible.  Does anyone know of a simple method to take a number of tangent section profiles and translate them into one plane such that one could create a cutter profile and subsequently check profile error?  If I can do this it will greatly reduce sanding labor and create better looking parts.  I have attached a sample file of the surface.  By no means does it need to be exact.  Currently we are still using the original turn key process and now that I have been looking at it they aren't using nearly a small enough radius tool.  Based on what we are making currently I would say .01"-.015" profile error would be fine, just as long as I generate intersecting surface curves to look the same.  I am making these on a 6 axis router, so tool posture isn't an issue.  Though being able to do them with a 4-axis would possibly be a beneficial thing in the future.

 

Finger Grooves.mcam