How 3D Scanning Is Rebuilding an Iconic RS500: Keith Tsang Interview | Vision148 Digital Engineering (Video)

Filmed at Coventry Metal Craft, the team demonstrates how high-precision scanning technology and PolyWorks software allow engineers to capture detailed measurements of the vehicle, align key reference points, and generate accurate digital models of the chassis and components.

This digital workflow makes it possible to: • Capture high-resolution 3D scan data of the vehicle • Combine scan data and probe measurements for precise engineering analysis • Generate cross-sections and features for CAD modelling • Build a complete digital record of the car for future development By creating a detailed digital dataset of the RS500, the Vision148 project is combining traditional coachbuilding craftsmanship with modern digital engineering, enabling accurate restoration, reverse engineering, and future development of this legendary performance car.

Video Transcript

[00:00:00] Hi, Adam Stanley here from the 3D Measurement Company. I’m here with Keith Tsang from PolyWorks and he’s the lead technical guy from the team in the UK. We are here at Coventry Metal Craft with Ian Howe from the Vision 148 project where we’ll be measuring and working on creating a digital data set for the Resto Mod RS 500 vehicle behind us.

Hi, my name’s Keith. I’m from 3D Scanners UK, and I’m the PolyWorks Technical Lead.

What datum strategy makes future re-scans repeatable with no drawings?

Typically you want to use anything that is repeatable and accessible. In this example we have clear access to the front struts, and potentially the rear ones as well. So we can actually measure the mounting holes. that way when the part is, through the process of the project, as it’s adding in more panels, as the car has been worked on, those areas have always been, always accessible.

So we can always log back in and continue measuring and, and adding to the data 

How do we combine scan + probed features so this becomes ‘engineering truth’?

With [00:01:00] the, um, Scantech system, we can import that data straight into our software PolyWorks. and with a direct plugin, we could also then start to probe.

And with that we are able to correlate your scan data and probe data together, straight off the bat. So anything we add in PolyWorks measurement wise by probing is directly on top of the scan data. So the engineers can get both of the world’s scan data, probe data, all the information that they need from it.

 What’s the best method for left/right symmetry checks on a chassis?

Within PolyWorks, we can actually create an updated plane down the middle of the vehicle. So once we’ve actually aligned the front struts, we can create an average of features giving us a centre line down the vehicle. and with that plane we can then actually, if we want to copy one side of the scan, duplicate that and then mirror it across this plane and then do an actual scan to scan comparison to see if there are any similarities or differences. 

If CAD is not initially available, what should we capture now to make that conversion easier?

So, with the idea of not having access to CAD initially, the idea is we want to make sure we scan as much as [00:02:00] possible, as they’re probably gonna do, probe as much as they can, get as much detail as possible. And then obviously they can potentially use PolyWorks’ reverse engineering package to actually convert the scan data into a CAD model. and with that CAD they could then bring that back into the inspection project, overlay the scan, and then actually get a, analysis to see what the difference is between that they, the CAD model that they produce and the original scan that they, scanned, scan, or any other future scans that they may produce for, the future production line.

 What’s the fastest way to produce a fabrication-friendly output (sections + hole tables)?

So PolyWorks has the capabilities of creating cross-sections through your scan, generating an outline which can be exported out to the CAD guys who can then sketch around, and model round if they needed to. The features that we’re measuring or the hole positions and sizes – those can be exported out in a table format, giving you X, Y, Z coordinates, sizes, IJK directions. but if you really wanted to, you can even export those actual features out straight into the CAD packages. So the CAD guys can then again, work around the actual, native entities of these features, in the packages.

[00:03:00] 

As the Technical Lead at Polyworks, what advantages do you believe the Trackscan Sharp S brings to the technology workflow?

The system is really useful , in many ways, A, speed – the fact that your system can capture such a large area.

You can scan a lot of the area quite quickly. You’re not needing to sticker the part necessarily if you don’t want to. ’cause everything’s tracked by the tracking system and the scanner. not only that, the fact that the system is wireless. So the idea is you’re not dangling cables around such a large area, especially in a working, busy working environment, you have people tripping over cables and stuff.

It’s a very useful system to have worked with. 

In a project of this nature – where individuals from various departments or locations collaborate on the same initiative – how does Data Loop facilitate their success?

The Data Loop can work in various areas of the business, giving everyone in the project full access to the data without the need of just sending PDFs and stuff. They get full interaction with a 3D environment.

They can view the result very quickly and instantly, and as soon as someone’s finished scanning, upload the result. They can access the information from a phone, tablet, or for a pc, but the bigger use cases are production areas. The idea is with all the results being [00:04:00] measured, it’s not just one person. It could be a team of people scanning hundreds of the same part for a big batch. That batch can then be analysed using SPC promotion data analytics, again for a business to be able to find trends of maybe, a tool wearing out, for example, and instantly stopping that from interrupting the production lines.

So, Data Loop just allows everyone to kind of interact and store in a central database.