How Handheld 3D Scanner Helps for Porsche Modifications

For automotive enthusiasts, Porsche isn't just a brand—it's a statement. Known for its precision engineering and distinctive performance, every Porsche model holds a legacy. But even the finest machines can be fine-tuned, and that's where Fabspeed Motorsport steps in, crafting performance-enhancing upgrades for Porsche owners who demand more.

Based in Fort Washington, Pennsylvania, Fabspeed has spent over 30 years perfecting custom exhaust systems, air intakes, and ECU tunes for high-end sports cars. Whether it's a vintage 911 or a modern Carrera, Fabspeed elevates both sound and speed with aftermarket components engineered for maximum performance. Learn how they use 3D laser scanning to streamline CAD modeling for high-performance auto parts.

The Challenge: Recreating OEM Parts Without Original Drawing

Creating tailor-made parts for vehicles—especially older or rare models—poses a unique engineering challenge. Fabspeed typically operates without access to engineering drawings. Engineers must digitally reconstruct original parts and redesign them to perform better, all without compromising compatibility.

Previously, this involved time-consuming manual fabrication: measuring by hand, welding, and countless iterations between the vehicle and the workbench. As Simon Indrele, Director of R&D at Fabspeed, puts it, “A lot of times these exhausts are symmetrical, but if you’re handcrafting something it doesn’t always go that way. And if you’re trying to prevent different areas from getting too much heat, doing that manually can be difficult.”

Enter Handheld 3D Laser Scanning

A turning point came five years ago when the team adopted a handheld 3D scanner. This technology allowed Fabspeed's engineers to capture complex geometries directly from the car, creating detailed 3D models of components like exhaust systems and air intake parts. With these scans, they could then design improved versions optimized for airflow, noise tuning, and thermal management.

Importantly, Fabspeed reversed its traditional workflow: instead of fabricating parts first and building fixtures later, they now design fixtures directly from CAD models. This approach enables repeatable, scalable production with higher precision.

Upgrading the Tech: Choosing the Right 3D Scanner

However, Fabspeed's original red-laser scanner began to fall behind as the automotive industry evolved. Modern cars feature highly reflective surfaces and mirror-like heat shields that red lasers struggle to read accurately—often requiring surface sprays and multiple passes to capture data.

To eliminate these inefficiencies, Fabspeed partnered with Digitize Designs to upgrade to the SCANTECH KSCAN-Magic handheld 3D laser scanner that uses blue laser technology to scan faster and more accurately—even on shiny surfaces—without the need for sprays or excessive markers.

Key Specs of KSCAN-Magic 3D Laser Scanner:

Accuracy: Up to 0.020 mm

Resolution: Up to 0.010 mm

Scanning Rate: 4,150,000 measurements per second

This scanner gave the R&D team the productivity boost they needed. “One major improvement has been the speed of the scanning,” Indrele says. “We don’t have to spray anymore, we just get up and go. We use fewer targets, and when we scan exteriors of cars (the shiny paint side of things) we no longer have to spray them down. So it just speeds everything up for us.”

Scanning a Porsche 911

One standout example involved a time-sensitive job on a Porsche 911 Carrera 4 GTS. Fabspeed needed to replace a discontinued muffler and had no digital files or supply chain to fall back on. Using the KSCAN-Magic's ultra-fast scanning mode, engineers quickly captured the geometry of the exhaust area, compared it against their digital library, and determined which muffler design would fit best—all in under an hour.

This rapid response allowed Fabspeed to stay agile and continue production without delays, proving the scanner's value in a high-stakes, fast-moving environment.

The Results: Speed, Precision, and Competitive Advantage

Fabspeed's investment in advanced 3D scanning technology has completely reshaped its approach to part development. With the KSCAN-Magic, the company now:

• Cuts scanning time in half
• Eliminates the need for scanning sprays
• Accurately captures shiny or dark surfaces
• Builds directly from CAD data
• Speeds up R&D cycles and production timelines

Most importantly, it empowers the team to maintain a competitive edge by offering faster, more reliable custom components for high-end vehicles.

“In businesses like ours where things are really hectic and fast, we’re moving high speed with every project,” Indrele says. “We’ve got to just get it done and move onto the next one. The KSCAN-Magic has been great for that.”

Transform Your Automotive R&D Operation

Want to streamline your automotive R&D like Fabspeed Motorsport? Discover the power of high-precision, handheld 3D scanning with SCANTECH. Explore our range of scanners or connect with a specialist to find the best fit for your needs.