Purpose -The purpose of the present work is to develop a methodology for making physical models of catchment areas and terrains by rapid prototyping (RP) using geographic information systems (GIS) data. It is also intended to reduce data loss by minimising intermediate data translations. Design/methodology/approach -The GIS data of a catchment area or a terrain were directly translated to an stereo lithography (STL) file. The STL surface was then manipulated in Magics-RP to obtain a solid STL part, which can then be downloaded to a RP machine to obtain a physical model or representation of a terrain or catchtment area. Findings -Intricate geometries of landforms were created with ease and great accuracy in RP machines. Terrain models were created in less time and lower cost than with conventional methods. Research limitations/implications -DEM ASCII XYZ (digital elevation model) data were used to input the required GIS data of specific terrains. Software can be developed for translation and manipulation of DEM, STL and other relevant file formats. This will eliminate any data loss associated with intermediate file transfer. Practical implications -Terrain models were created with ease and great accuracy in RP machines. It takes less time and can be done more costeffectively. Terrain models have intricate geometries and for complex models, it may take months to make using conventional methods. Originality/value -STL surfaces were obtained directly from GIS data for terrain modeling. This work fulfils the need of terrain modeling for catchment management, town-planning, road-transport planning, architecture, military applications, geological education, etc.