Mercedes C63 Interior 3D Scan — Automotive Custom Shop
A custom shop needed exact digital geometry of a Mercedes C63 cabin to build custom-fit replacement and upgrade parts. We scanned the dashboard panels, door trims, and centre console, then delivered clean, print-ready STL geometry.
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Complexity rating
Large freeform surfaces with tight fit tolerances, combined with mixed sensitive materials (leather, Alcantara, semi-gloss trim) that required surface preparation, marker-based alignment, and careful section-by-section scanning to minimise stitching.
Availability
Months of lead time
Part: Mercedes C63 interior cabin parts
Client: Automotive custom & restoration shop
What made this difficult
The client wanted to develop custom-fit interior parts for a Mercedes C63 — dashboard panels, door trims, and the centre console — but no CAD data exists for these trim pieces. OEM interior components are complex freeform surfaces with tight mounting tolerances, and measuring them by hand is effectively impossible.
Several of the original trim pieces are only available through the dealer with long lead times, and the client wanted the freedom to modify and upgrade the parts rather than simply replace them. Without accurate digital geometry, any custom part would be guesswork.
The interior mixed difficult surfaces — semi-gloss trim, leather, and Alcantara — which are exactly the materials that defeat cheaper scanners and require careful preparation to capture cleanly.
How we solved it
3D scanning → mesh → optimisation → reverse engineering → print-ready files.
We 3D-scanned each interior component with our Shining 3D EinScan HX2, capturing every contour, radius, and mounting point at up to 0.04 mm accuracy. Sensitive surfaces were prepared with a safe, removable scanning consumable before capture, and Capilier reference markers were used to lock alignment across the deeper, hard-to-reach sections of the console.
The raw point cloud was converted to a mesh and repaired in the EinScan software, then optimised in Geomagic — hole-filling, decimation, and surface preparation — to produce clean, watertight geometry.
From the optimised mesh we delivered print-ready STL files, and where the client wanted parametric control we reverse-engineered selected features in Fusion 360 / SolidWorks. Each part was verified against the original before manufacturing.
Beyond a like-for-like copy
- The client wanted more than a like-for-like copy: mounting bosses were reinforced and wall thicknesses adjusted so the custom parts print and fit more reliably than the originals.
- Because the geometry is now digital, the client can iterate finishes and variants (different trim inserts, cutouts for switches) without re-scanning — the scan becomes a permanent, reusable base.
The full process, phase by phase
Each phase below includes a screen recording of the actual software workflow.
3D Scanning on EinScan Software
Shining 3D EinScan HX2 · EinScan software
Capturing the dashboard panels, door trims, and centre console. Sensitive surfaces are prepped with a safe scanning consumable and Capilier markers lock alignment across deep sections. Screen recording of the live capture session.
Mesh Repair in EinScan Software
EinScan software
Converting the point cloud to a mesh and repairing it — closing gaps, removing noise and outliers, and stitching sections into a single continuous surface. Screen recording of the mesh repair workflow.
Mesh and STL Optimization in Geomagic
Geomagic
Refining the mesh in Geomagic — hole-filling, decimation, and surface preparation — to produce a clean, watertight, print-ready STL. Screen recording of the optimisation steps.
Reverse Engineering in Fusion 360 / SolidWorks
Autodesk Fusion 360 · SolidWorks
Where parametric control was needed, selected features were rebuilt as editable CAD with proper tolerances and reinforced mounting geometry. Screen recording of the reverse-engineering session. (Applied to the parts the client wanted to modify.)
What the client received
Files delivered
- Print-ready STL files for each scanned component
- Editable Fusion 360 / SolidWorks CAD for the parts modified for custom fit
- STEP / IGES available on request for engineering use
- Digital archive of the scan data for future variants and re-orders
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