Summary
Key results
Reliable digital basis for planning railcar modifications
Lower risk of fit issues before physical implementation
Accurate railcar geometry for modification design
The client needed precise 3D models of 2 trains covering 8 railcars to support the design of new components before physical implementation. The required scope included full railcar body shells and selected internal and external elements. The models had to provide a geometric reference for further design work and virtual fit checks.
The client-provided scans were not always complete. Noise affected complex geometry such as wheels and driver control desks, while gaps in the point clouds made areas such as window openings harder to reconstruct accurately. The models also had to meet defined accuracy requirements: up to 20 mm deviation for exterior bodywork and 2 mm for key components.
Sii Poland was engaged to turn the scan data into 3D models suitable for further design work and reduce the risk of fit issues during implementation.
End-to-end reverse engineering from scan data
One Sii Poland specialist managed the full workflow, from reviewing the client-provided scans to delivering final 3D models. The work covered scan verification, point-cloud preparation, mesh generation, geometry reconstruction, and model refinement based on client feedback. The specialist also documented a working procedure covering each stage from opening the point cloud to final model creation.
The scope included:
- Reviewing scan quality and identifying noise, missing data, and areas requiring additional verification
- Cleaning and processing point clouds before generating meshes for geometry reconstruction
- Building 3D models of full railcar body shells and selected internal and external components
- Comparing the reconstructed geometry with the scan data against the required tolerances
- Correcting window openings, complex components, and other details where the original data was incomplete or insufficiently accurate
- Refining models during review cycles, including updates based on more precise point clouds supplied by the client when needed
- Delivering the final models in STEP format for further design work
Sii used CloudCompare and MeshLab to analyze and process the scan data and SolidWorks to create the final models. Client reviews were handled iteratively, with the first delivery typically followed by 1 correction round focused mainly on accuracy.
More controlled railcar modification design
The client gained accurate 3D models of 8 railcars that provided a practical basis for designing new components and structural modifications. By checking fit in a virtual environment before physical implementation, the organization could reduce the risk of fit issues and approach planned changes with greater confidence.
Key results
- 3D models delivered for 8 railcars across 2 trains
- Approximately 1.5 months required to remodel each train
- Models prepared against accuracy requirements of up to 20 mm for exterior bodywork and 2 mm for key components
- STEP models delivered for the design of new railcar components
- Lower risk of fit issues through virtual checks before physical implementation
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