Reverse Engineering in the Automotive Industry: From a Classic Corvette to Electric Buses
Reverse engineering is gaining increasing relevance in the automotive sector – from reconstructing unavailable parts to developing modern aerodynamic components and electrifying existing vehicles. Thanks to 3D scanning for reverse engineering, it is possible not only to recreate a physical object, but also to prepare technical documentation and production-ready data.
At SCANM2, we have carried out dozens of such projects. Below we present three representative examples.
1. Reconstruction of a Corroded Body Part of a Classic Car: Chevrolet Corvette
A specialist in the restoration of vintage vehicles contacted us with a request to recreate a body element in a classic Chevrolet Corvette (from the 1960s) that had suffered from extensive corrosion. The original part was no longer available, and neither technical documentation nor replacement parts could be sourced.
What we did:
- We performed reverse engineering scanning using a handheld 3D laser scanner with an accuracy of 0.02 mm.
- Based on the point cloud, we developed a detailed 3D model in STL format.
- The client used the model to create a mold and manufactured the component from new-generation composites – carbon fiber and epoxy resin.
Result: The new part matched the original bodywork perfectly, and the entire process took less than two weeks. Thanks to reverse engineering with 3D laser scanning, we successfully recreated a component that had long disappeared from the market.
2. Measurement of a Bus Undercarriage for Electric Conversion
A technology company working on converting combustion engine vehicles to electric power approached us to carry out precise measurements of a city bus undercarriage.
What we did:
- We performed a full 3D laser scan of the undercarriage.
- The measurement accuracy was 0.1 mm, allowing us to capture all mounting points, curvatures, and the complete geometry of the frame.
- We delivered a complete data package: a 3D model, 2D drawings, and technical documentation.
Result: The client was able to design their own battery module and installation system, which fit perfectly with the original structure. This avoided the need for costly modifications.
3. Development of a New Aerodynamic Bumper for a Heavy Vehicle
A design team developing aerodynamic bumpers for trucks needed an accurate 3D model of a specific vehicle to create a new component that would improve airflow and reduce fuel consumption.
What we did:
- We scanned the heavy-duty vehicle (brand anonymized due to RODO regulations).
- Using spatial data, we built a precise CAD model.
- The client’s designers created a prototype bumper, which was then 3D printed using FDM technology and tested in real conditions.
Result: Thanks to 3D reverse engineering, the client reduced design time by 40% and avoided expensive design errors.
How SCANM2 Supports the Automotive Sector
As a company specializing in reverse engineering services, we offer:
- 3D scanning of vehicles and their components,
- preparation of STL/STEP/DWG models,
- 2D and 3D documentation for workshops, manufacturers, and design teams,
- fit and collision analysis,
- component optimization for manufacturing.
The 3D scanners for reverse engineering we use ensure high precision and enable non-invasive work even with very delicate parts.
Do You Have an Unusual Vehicle or Prototype?
Contact us – we will provide a free quotation, and our engineers will recommend the most effective solution. With SCANM2, even the oldest vehicle can be brought back to life with the help of 3D reverse engineering.