A tooling system comprises a plurality of elements arranged in an array, the elements of the array being movable between a closed position in which the elements contact one another and are secured in position, and an open position in which the elements of the array are spaced apart and are capable of vertical movement relative to one another, characterized in that the tooling system further comprises means for retaining the elements of the array in a plurality of different relative vertical alignments. A method of operating the tooling system is also described, which method of operating includes at least the steps of moving the elements of the array into a first vertical alignment, machining the free ends of the elements according to a predetermined pattern and moving the elements of the array into a second vertical alignment in which the machined ends of the elements produce a desired surface contour.