Rapid Prototyping(RP) techniques have their unique characteristics according to the working principles: stair-stepped surface of parts due to layer-by-layer stacking, low build speed caused by line-by-line solidification to build one layer, and additional post processing to improve surface roughness, so it is required very high cost to introduce and to maintain of RP apparatus. The objective of this study is to develop a new RP process, Variable Lamination Manufacturing using linear hotwire cutting technique and expandable polystyrene foam sheet as part material(VLM-S), and to investigate characteristics of part material, cutting characteristics by using linear hotwire cutting system and bonding. Experiments were carried out to investigate mechanical properties of part material such as anisotropy and directional tensile strength. In order to obtain optimal dimensional accuracy, surface roughness, and reduced cutting time, addition experiments were performed to find the relationship between cutting speed and cutting offset of hotwire, and heat generation of hotwire per unit length. So, adhesion strength tests according to ASTM test procedure showed that delamination did not occur at bonded area. Based on the data, a clover-shape was fabricated using unit shape part(USP) it is generated hotwire cutting. The results of present study have been reflected on the enhancement of the VLM-S process and apparatus.