Size reduction decomposition for rapid prototyping large objects

In this paper, a size reduction decomposition methodology for making large prototypes in Rapid Prototyping (RP) process is proposed. In the proposed methodology, the series of decomposition processes begin with overhanging features, then features which induce poor surface quality on a prototype. The aim of the methodology is not only for splitting a model into a number of smaller components, but also for reducing the amount of support structures required and improving the prototype surface quality. As a result, a large prototype can be produced by assembling all its components which are fabricated separately from RP process.