Three dimensional model and mold making method using thick-slice subtractive fabrication

A novel method for manufacturing a complex three dimensional object from a computer generated model comprising:

• (a) loading data representing said computer generated model into a computer control program;
• (b) loading a set of fabrication machine parameters representing at least one subtractive fabrication together with a set of fabrication material parameters representing fabrication material properties, into said computer control program;
• (c) using said computer control program to automatically specify a model fabrication which produces, by subtractive machining alone, a preferable plurality of slabs, whose number is a minimum subject to constraints imposed by said fabrication machine parameters and said fabrication material parameters, with each one of said plurality of slabs having a sufficient thickness to allow a subset of model surfaces, from said computer generated model, to be faithfully and accurately fabricated within at least one slab of said plurality of slabs, without necessitating the entire removal of said subset model surfaces from said slab, whereupon when said plurality of slabs are fabricated in accordance with instructions from said computer control program and whereupon when said plurality of slabs are aligned, assembled and joined together, the resultant assembly will comprise a complete reproduction of said complex three dimensional object bounded by said slabs, with said complex three dimensional object being preferably temporarily retained within said plurality of slabs until the time of said complex three dimensional object removal;
• (d) at the time of manufacture, subtractively fabricating each one slab from said plurality of slabs, orienting each said slab, aligning each said slab with a previous slab from said plurality of slabs, and in proper sequence, assembling each said slab, by preferably using a bonding and fixturing for composite structure which preferably temporarily retains said complex three dimensional object within said composite structure until the time of said complex three dimensional object removal.