Our engineers took the scan data into a CAD program and separated the Falcon into its component parts.  Using this data, our modelers began the process of building the first prototype by outputting all of the the major body forms of the Falcon using a 3D printer.  This provided them with precisely scaled copies of the upper and lower hulls, the sidewalls and all of the surface panel lines onto which they would begin to apply the myriad of miniaturized details.

Using the scan data, where they could, they also printed out miniature detail parts. For those parts which were too small to accurately print, they scratch built copies, referencing the extensive photographs and measurements acquired directly from the special effects miniature.  Our initial thoughts had been to make the entire body in die-cast, so this first prototype was assembled with this goal in mind.