Traditional automated machining and material deposition systems are not easily scalable and can be expensive. This thesis presents a less expensive, scalable alternative – a seven degree-of-freedom (DOF) cable-suspended robot (CSR) for use in 3D sculpting, with further applications in automated machining, rapid prototyping, and construction. Two important novelties are a passive pose metrology system independent of the active drive system, and a simple yet non-traditional method of cable tensioning utilizing a spring mounted inline on the seventh active cable. This thesis presented the final design, construction, and controller implementation using a classical joint-level PID real-time control architecture, and the novel implementation of a 3D digitizer, called MicroScribe, as a master input device. The control system was applied to a full-scale robot at NIST where a scaled 3D duplication was performed using a MicroScribe to trace a maquette while the CSR cut an enlarged duplicate out of polystyrene in real-time.