Rapid Tool Design for an Electric Jetski Using 3D Scanning

What does it take to stay ahead in the rapidly evolving marine vehicle industry, where every second counts? When DDD Control Kft., one of the top providers of 3D technology and post-processing software, set out to develop a new version of an electric jetski, they faced a key challenge: to design and manufacture a positive tool that perfectly aligned with an existing bottom hull model while reducing development time.

NimbleTrack is Scanology’s cutting-edge wireless optical 3D scanning system designed for flexible, high-precision measurements. It operates at a high frame rate of 120 FPS, achieving accuracy up to 0.025 mm and a volumetric accuracy of 0.064 mm across its 3.2-meter tracking range. Featuring a fully wireless design and marker-free optical tracking, NimbleTrack allows engineers to capture 3D data quickly and effortlessly — even for large or complex parts.

To meet this challenge, DDD Control integrated Scanology's NimbleTrack wireless optical 3D scanning system into every stage of the design and validation process. Rather than limiting 3D scanning to final inspection, they used it as a core tool for real-time validation, design iteration, and geometry optimization. The result was a faster, more accurate, and cost-effective workflow that demonstrated the transformative potential of 3D scanning in tool design.

Scanning of the Legacy Component

The project began with the precise digitization of the jetski's existing bottom hull. Using Scanology NimbleTrack, the team captured a high-resolution 3D model of the component with submillimeter accuracy of up to 0.025 mm.

This digital reference served as the foundation for all subsequent design work. It ensured geometric continuity between the legacy hull and the new version while eliminating guesswork from the design phase. The wireless and marker-free tracking capability of NimbleTrack also allowed engineers to scan large, complex surfaces effortlessly and in real time.

Geometry Modification for the Bottom Hull

With the scan data in hand, engineers extended the bottom hull to meet the new jetski's design specifications. Working directly with accurate 3D data enabled them to modify proven geometries confidently, ensuring that all changes maintained aerodynamic and hydrodynamic performance.

This approach significantly reduced the time spent on manual adjustments and physical prototyping—key steps that often introduce delays in traditional workflows.

Designing the Upper Hull

Once the updated bottom hull model was completed, attention turned to designing the upper section of the jetski. The design team focused on aesthetic appeal, ergonomic considerations, and structural alignment with the extended bottom part.

Because the lower hull data was already verified and precise, the upper design process progressed smoothly, with fewer uncertainties regarding fitment or dimensional consistency.

Manufacturing and Validation of the Bottom Hull

After the design phase, the modified bottom hull was manufactured. Before moving forward, the team used NimbleTrack 3D scanning once again to validate the hull’s accuracy.

By overlaying the scan data onto the CAD model, DDD Control identified minor deviations early on. This quick feedback helped prevent potential alignment issues during later stages, saving both time and material costs.

Design Adjustments for the Upper Hull

The geometric insights gained from scanning the manufactured bottom hull guided targeted updates to the upper hull design. This proactive correction loop allowed the engineers to refine the fit between components before physical fabrication began.

This level of iterative precision would have been impossible without real-time scanning feedback, which drastically minimized the risk of mismatch between the upper and lower assemblies.

3D Printing of the Upper Part

The upper hull was then 3D printed based on the refined design. Additive manufacturing offered excellent flexibility and speed, enabling rapid validation of the adjusted model. The printed prototype provided a tangible way to assess assembly, surface quality, and functional compatibility.

Geometry Validation of the Printed Upper Part

To confirm that the printed upper hull matched design expectations, the team performed another scan with NimbleTrack. The comparison showed that earlier adjustments successfully compensated for deviations, resulting in a near-perfect geometric match.

This step validated the entire digital workflow and demonstrated how continuous 3D scanning feedback ensures design integrity at every milestone.

Designing Additional Fitting Components

With both main components validated, DDD Control designed secondary elements — such as connection interfaces and fitment features — based directly on the scanned geometry of the real parts. This ensured that all supporting structures were dimensionally consistent and ready for seamless integration.

Final Fit and Validation

The final assembly underwent one more comprehensive 3D scan to verify the accuracy of all surfaces and overall alignment. The validation confirmed dimensional integrity and precise fit across the entire positive tool.

By closing the loop with one last scan, the team guaranteed that the final tooling met stringent accuracy standards without unnecessary iterations or rework.

Outcome

The integration of Scanology's NimbleTrack 3D scanning system proved to be a game-changer for this project.

The scanning process reduced validation time by over 60% compared to traditional inspection methods.

Early detection of dimensional deviations helped avoid costly rework and material waste.

The project was delivered on a tight schedule while maintaining high precision and confidence in the final tooling outcome.

Thanks to the real-time geometric insights provided by NimbleTrack, DDD Control achieved a smoother workflow from concept to completion — turning a complex design challenge into a streamlined, data-driven process.

Key Takeaways

3D scanning across all stages: Instead of using scanning only for quality control, DDD Control applied it throughout the entire design and manufacturing cycle, from reverse engineering to in-process validation.

Fast, wireless, and accurate: Scanology's NimbleTrack enabled quick, repeatable scans of large parts without markers or elaborate setup, ensuring minimal disruption to ongoing production.

Shorter iteration cycles: Real-time geometric feedback prevented fitment issues and accelerated decision-making.

Precision-driven design: Continuous scanning ensured that every design update aligned perfectly with real-world conditions.

Conclusion

This case study highlights how 3D scanning technology is reshaping rapid tool design. By combining Scanology's NimbleTrack with iterative CAD modeling and additive manufacturing, DDD Control not only optimized accuracy but also accelerated the entire product development timeline.

As industries increasingly move toward digitization and intelligent manufacturing, workflows like this demonstrate how integrated 3D scanning solutions can drive innovation, from marine vehicles to aerospace components, with precision, agility, and confidence.