Rapidly making a contoured part

A method of rapidly producing a part having complex free-form, undercut or hidden internal surfaces, comprising:

• (a) designing a three-dimensional solid computer graphic model of said part and said internal surfaces;
• (b) sectioning said model into computer graphic members which are selected from blocks and slabs, said sectioning being to facilitate machining access into and penetration of two or more section sides of each graphic member to permit machining replication of the internal surfaces;
• (c) within a computer, generating machining tool paths for each graphic member that will replicate said interior surfaces and sectioning planes,
• (d) physically carving a solid non-graphic physical member along said machining tool paths to replicate each graphic member, said machining being carried out by accessing said two or more section sides to carve into and penetrate said sides to create contours that meet smoothly between mating solid members;
• and;
• (e) securing said machined solid members together to form an assembly that identically replicates said model as a functional usable unitary part.