3D Scanning Solutions for Automotive Inspection and Vehicle Digitization

Introduction

Manufacturers and suppliers in automotive industry must ensure every component meets strict quality standards, from small plastic parts to full-sized vehicles. SCANOLOGY 3D scanning solutions, including SIMSCAN and TrackScan Sharp, provide fast, accurate, and versatile inspection tools that help automotive companies improve quality control, reduce inspection time, and support digital manufacturing. This article highlights two real-world applications of SCANOLOGY scanners in the automotive sector.

Case 1: High-Precision Scanning for Faurecia SE

Client Overview

Faurecia SE is a leading global automotive supplier headquartered in Nanterre, France, providing vehicle interiors and emission control technologies. As of 2022, Faurecia equipped one in every two vehicles worldwide, making precision and quality control essential in its production process.

Part Features and Inspection Needs

Faurecia required inspection of small and medium-sized plastic parts used in vehicle interiors, as well as calibration of control templates. These components often involve intricate geometries, precise functional surfaces, and reflective or glossy finishes. Even minor deviations could affect part assembly, performance, or aesthetic quality. Accurate validation of these components' dimensions and shapes was therefore essential, both to ensure compliance with design specifications and to maintain consistent production quality.

Measurement Challenges

• Several factors made inspection difficult. The small and intricate nature of the parts required extremely high measurement accuracy.
• Many parts had reflective surfaces that interfered with optical measurements, complicating traditional scanning methods. In addition, inspections had to be completed quickly to avoid slowing down the production line.
• Manual inspection methods or traditional contact-based tools were insufficient, as they were slow, prone to errors, and often unable to capture fine surface details. Some even require extra preparation, such as spray coating reflective surfaces. The growing demand for speed, precision, and flexibility called for a more advanced solution.

SCANOLOGY 3D Solutions and Benefits

To meet these requirements, SCANOLOGY's SIMSCAN 30 3D laser scanner was deployed. This high-precision scanner delivered 20-micron accuracy while completing each scan in under 10 minutes.

Importantly, it handled reflective surfaces without requiring sprays, simplifying preparation and reducing production delays.

Using SIMSCAN 30, Faurecia could efficiently scan both small parts and calibration templates, generating precise 3D measurements and high-quality color maps. These color maps allowed engineers to visually identify deviations, optimize part geometries, and make adjustments to maintain tight tolerances.

The combination of speed, accuracy, and versatility significantly reduced inspection time, improved workflow efficiency, and ensured consistent quality across all inspected components.

Key Benefits

• Rapid inspection of complex components
• High-precision measurement (0.020 mm)
• Spray-free scanning of reflective parts
• Visual deviation analysis with color maps

Case 2: Full Vehicle Scanning

Client Overview

In another project, a client required a full 3D scan of an entire vehicle to produce a detailed digital display. The challenge was to capture every interior and exterior detail accurately while protecting the vehicle's paint from damage, meaning that no markers could be applied. This project demonstrated the capacity of SCANOLOGY's 3D scanning solutions to handle large-scale, complex objects efficiently.

Vehicle Features and Inspection Needs

The vehicle measured 5.2 meters long and 2 meters wide, with intricate interiors and black ceilings. The client needed a full 3D model quickly, with high accuracy, and required a single operator to complete the scan within 1.5 hours.

Measurement Challenges

• Scanning a full-sized vehicle introduced several challenges. First, the large scale meant that a single scanner alone could not cover the entire object efficiently.

• Interior surfaces and black areas, particularly the ceiling, were difficult to capture with traditional scanners due to low reflectivity.

• Marker-based positioning was not an option for the vehicle's exterior, as it could damage the vehicle's paint and increase setup time.

• Additionally, the entire scanning process had to be completed in just 1.5 hours by one operator, adding time constraints that traditional measurement methods could not meet.

SCANOLOGY 3D Solutions and Benefits

SCANOLOGY deployed a combination of TrackScan Sharp 49 and SIMSCAN 42 to address these challenges. TrackScan Sharp 49, using the Super-Coordinate solution, scanned the exterior from 2–3 positions and generated a complete exterior dataset. SIMSCAN 42 then scanned the interior, including dark surfaces, to produce complementary data. The two datasets were merged into a full, accurate 3D model of the vehicle.

This combined solution delivered high efficiency, enabling a single operator to complete the scan in 1.5 hours while maintaining high accuracy. Marker-free scanning protected the paint, and SIMSCAN 42's capability to handle dark surfaces ensured no loss of detail inside the vehicle. Compared with conventional solutions, this approach reduced complexity, minimized scanning time, and produced a high-fidelity digital representation suitable for visualization and analysis.

Key Benefits

• Complete vehicle scanning in 1.5 hours by one operator
• High-accuracy 3D data
• Marker-free scanning to protect paint
• Efficient capture of dark and complex surfaces
• Simplified workflow with fewer scan positions

Conclusion

SCANOLOGY's 3D scanning solutions transform automotive inspection and digitization. For small and medium-sized parts, SIMSCAN 30 delivers micron-level precision, fast scanning, and workflow efficiency. For full-sized vehicles, the combination of TrackScan Sharp 49 and SIMSCAN 42 provides comprehensive, high-accuracy 3D models quickly and safely.

By integrating SCANOLOGY 3D scanners, automotive manufacturers and suppliers can:

• Ensure precise quality control
• Reduce inspection time and labor costs
• Digitally capture complex components and vehicles
• Support digital manufacturing and visualization

SCANOLOGY 3D scanning solutions are the preferred choice for automotive companies seeking accuracy, speed, and versatility in inspection and vehicle digitization.