Abstratct- In this paper, first, a number of emerging technologies for rapid manufacturing of components are introduced and their application in manufacturing aeronautical structural components is discussed. Then, a novel method for generation of sectional contour curves directly from the cloud point data is presented. The proposed method computes contour curves for rapid prototyping model generation through adaptive slicing, data points reducing and B-spline curve fitting. The Proposed procedure was programmed in MATLAB software package to perform all computational effort in a single software system. The method has been applied to a wing-fuselage connector component of an existing fighter aircraft to create its layered model for rapid manufacturing. 3D comparison of the developed model and the digitized cloud point data reveals that 95% of the data points have a maximum deviation of 0.5 mm, which is a reasonable accuracy compared to the component size. The simplicity and effectiveness of the proposed method, as demonestarted by our experiments, confirms that the algorithm can be practically used for rapid prototype manufaturing of aeronautical structural components with an adequate accuracy.