This paper presents process planning methods for Subtractive Rapid Prototyping, which deals with
multiple setup operations and the related issues of stock material management. Subtractive Rapid
Prototyping (SRP) borrows from additive rapid prototyping technologies by using 2½D layer based
toolpath processing; however, it is limited by tool accessibility. To counter the accessibility problem,
SRP systems (such as desktop milling machines) employ a rotary fourth axis to provide more complete
surface coverage. However, layer-based removal processing from different rotary positions can be
inefficient due to double-coverage of certain volumes. This paper presents a method that employs STL
models of the in-process stock material generated from slices of the part along the rotation axis. The
developed algorithms intend to improve the efficiency and reliability of these multiple layer-based
removal steps for rapid manufacturing.Mechanical Engineerin
