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This paper presents the integrate procedure for the documentation and fabrication of the 3D Digital Terrestrial Model (DTM) of inaccessible and rough surfaces. The proposed procedure combines the use of modern Image Assisted Total Stations (IATS) with Rapid Prototyping (RP) Technology. The determination of the measurement accuracy, as well as, the a-priori estimation of σo of the surface creation is achieved by using the Monte Carlo technique and the least square method. Also, basic concepts and principles of RP technologies are presented. The application of the procedure was realized at the difficult and inhospitable area of the central crater “Stefanos” on Nisyros Island's Volcano, Greece. The a-priori calculation of the minimum essential scanning step, as well as, the testing use of two IATSs is included. Additionally, the elaboration and the special algorithms used for the actual RP fabrication of the crater's tangible model are illustrated. Finally a scholastic check of the model's reliability is applied.