Method and system for reproduction of an article from a physical model

The surface of a clay model is laser scanned to obtain a set of laser scan data. The scan data provides X, Y and Z values of the part. The raw scan data is then preferably edited to smooth, filter, and pre-process it for further use. A first algorithm implemented at an engineering workstation is used to create a first set of equations which represent a three-dimensional surface of the model from the edited set of scan data. A second algorithm utilizes known wire frame data for the part model to compute a second set of mathematical equations. The first set of equations and the second set of equations represent surface(s) and characteristics of the model in a recorded format usable by CAD-based systems to facilitate part design and tool construction. A third algorithm generates an NC tool path data from the first and second set of equations. The NC tool path data may be utilized at a machining center to cut a production part mold, or a direct reproduction of the model. The method may be utilized iteratively from different views of the model to obtain data which represents multiple aspects or facets of the model.