The SolidWorks Expert

FROM SCAN DATA TO A FULLY PARAMETRIC AIRCRAFT MODEL!...

In this project, we carried out a complete reverse engineering workflow of a full-scale Twin Otter aircraft—starting from raw 3D scan data all the way to a clean, fully rebuildable CAD model.

The process began in Geomagic Design X, where the scan data was analyzed, cleaned edited and defeatured in a way to reach the original main surfaces of the Aircraft main features while trying to preserve the curvature continuity and features identity as much as possible. Using a combination of region-based surfacing, accurate sketch extraction, and controlled manual feature recognition, we translated complex organic geometry into precise engineering references. Every critical section—from fuselage profiles to wing geometry and control surfaces—was carefully reconstructed to preserve both accuracy and design intent.

The real value, however, came in the next stage.

All key sketches and references were transferred into SOLIDWORKS, where the aircraft was rebuilt from the ground up using a structured, fully parametric feature tree. This allowed for:

* Clean and editable geometry
* Design intent-driven modeling
* Full control over future modifications
* Manufacturing-ready outputs

The result is not just a model that “looks right,” but one that behaves like a native CAD design—robust, editable, and ready for engineering use.

This type of workflow is essential when scan data alone isn’t enough, and a true CAD reconstruction is required for redesign, analysis, or production.

If you're working with scan data and need to convert it into usable engineering models, this is exactly the level of control and precision you should expect.

Check out the latest HAAS paint scheme from our partners at NBARCPARTS on our amazing F1 Velocis V2!...

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Just wrapped up one of our latest design projects — a Cyclops head sculpture.

This project was a great opportunity to practice some surfacing and hybrid modeling techniques, while also applying Power Surfacing sub-d modeling within SolidWorks to achieve complex organic forms.

From the digital CAD model to the final manufactured piece, it’s always exciting to see ideas take shape in reality.

Sharing both the CAD model and the finished product here to showcase the full design-to-production journey.