Upgrade Vehicle Modification Workflows with Advanced 3D Solutions

The automotive industry is developing rapidly, with increasing demand for customized vehicle solutions driven by consumer preferences and technological advancements. From aftermarket upgrades to fully re-engineered vehicles, modification services have become an essential part of the automotive value chain. Design and engineering firms must now deliver high-precision, short-turnaround services while maintaining high standards in quality and consistency.

In this context, 3D scanning technology has become a transformative tool. It enables companies to capture accurate geometrical data of existing vehicles, which is crucial for modifications, reverse engineering, and digital design validation. Among the leaders in this space, SCANTECH's high-performance 3D solutions are playing an important role in helping firms streamline their workflows, boost accuracy, and cut down project lead times.

Introduction of the Client

LUSSO Design Engineering, headquartered in India, is one such company that has successfully integrated 3D scanning into its vehicle modification projects. Initially known for offering design services in the rail sector, LUSSO quickly expanded its scope to include automotive body and chassis engineering in response to growing customer demands. Today, LUSSO offers end-to-end services that span vehicle styling, structural design, and small-scale production.

For a recent automotive project, LUSSO undertook a comprehensive modification initiative involving four Tata Motors vehicles: Harrier, Safari, Tiago, and Nexon. To ensure precision throughout the design and development phases, the company required high-quality 3D scan data of both the interior and exterior of each vehicle. This scan data would serve as a critical reference point for tailoring the vehicles to the exact needs of their customers.

Feature of the Part to Be Inspected

The scanning scope included both the outer body and the cabin interiors of the four different vehicle models. Each of these surfaces presented unique challenges, from glossy exterior finishes to intricate dashboard geometries. Capturing such complex shapes with high accuracy required a powerful and adaptable scanning solution. Both high-resolution data capture and reliable alignment are demanded to meet expected dimensional tolerance.

Measurement Challenges

Several challenges emerged during the course of the project:

Non-Invasive Scanning Requirement: Traditional scanning methods often require sticking markers directly onto the vehicle surface, which can damage delicate finishes or leave residue. In this case, however, the customer specified that no markers should be applied to the car surfaces.

Tight Schedule: The entire scanning process needed to be completed in just two days. This included scanning all four vehicles inside and out.

Software Verification: The scan data needed to pass a quality check using a widely-used industrial design software that is particularly stringent when it comes to surface data validation.

Limits of Previous Measurement Methods

Before adopting advanced 3D scanning, vehicle modification firms like LUSSO often relied on manual measurements or basic digitizing tools. These traditional methods suffered from several drawbacks:

Low Speed: Manual techniques are time-consuming and labor-intensive.

Inaccuracy: Tape measures or mechanical gauges can't reliably capture complex curves or interior structures.

Inconsistency: Repeated measurements can vary depending on the operator, resulting in potential design errors.

Data Gaps: Traditional methods can leave voids in data, especially in hard-to-reach or highly detailed areas.

Given these limitations, LUSSO needed a robust and precise 3D scanning solution that could meet the demands of modern automotive engineering.

SCANTECH's 3D Solution and Its Benefits

To meet the project's complex requirements, our partner Electronica Mechatronics Systems helped the company deploy SCANTECH's TrackScan Sharp optical 3D scanning system. This cutting-edge system offered LUSSO a comprehensive solution to their challenges.

Key Features of the SCANTECH Solution Included:

Dynamic Tracking Mode: Enabled real-time capture without sticking markers on vehicle surfaces. Instead, 12 mm magnetic reflective markers were used around the scanning area, making the process non-invasive and surface-safe.

High Accuracy and Speed: The TrackScan Sharp achieves an accuracy well within the required threshold. With a scanning rate of 2.6 million measurements/s and a tracking range of up to 6 meters, it enabled fast data capture of entire vehicle surfaces.

Adaptable Tracking Distance: Equipped with three types of tracking distance—standard, medium, and large—the system could adjust to different part sizes and shapes, from dashboards to bumpers.

Portable and Flexible: The 3D scanner supports both wired and wireless operation, allowing for quick setup and easy movement across different scanning locations and vehicle positions.

Seamless Data Validation: The collected scan data passed quality checks in Alias software without the need for rework, proving its fidelity and compatibility with downstream design workflows.

Thanks to these advantages, the team completed all scans within the two-day deadline, with no compromises on data quality or completeness.

3D Scanning in Vehicle Modification

This case exemplifies how high-precision 3D scanning technologies are revolutionizing the vehicle modification process. By partnering with Electronica Mechatronics and leveraging SCANTECH's TrackScan Sharp system, LUSSO Design Engineering overcame time, accuracy, and data validation challenges in a demanding multi-vehicle project.

The scan data is now being used as a reference for modifying the Tata Harrier, Safari, Tiago, and Nexon models to meet customized requirements. As vehicle design becomes increasingly personalized and data-driven, 3D scanning will remain a core enabler of innovation in the automotive sector. For companies like LUSSO, embracing such technology is not just an upgrade—it's a strategic investment in future-ready engineering.