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Focuses on Profiled Edge Lamination (PEL) tooling and the development of a new alogrithm, the Adaptively Vectored profiles Projection (AVPP), Describes the geometrical relationships and heuristics for determining the abrasive water jet (AWJ) cutting orientation, position, and cutting sequence. The algorithm has ben implemented in a software program that can be used to generate machining code form PEL fabrication using a 5‐axis CNC AWJ cutting machine. Based on an investigation of cutting trajectory behavior on a challenging benchmark tool shape, the algorithm generates cutting paths that are well behaved, avoid any excessive leading or lagging of the AWJ cutting nozzle, and conform exactly to the original STL geometry. finally, an aluminium PEL tool used for hydroforming a production aluminium aircraft part was successfully fabricated using the AVPP algorithm and then demonstrated.