Front and rear bumper bodykit, from scan to tooling

The problem

The client had a bodykit on a physical vehicle but no CAD. Their previous toolmaker had produced parts that did not fit consistently, and the rear bumper interface to the body was out by several millimetres at the wheel arch.

What we did

• Scanned the complete vehicle and the existing kit parts, then cleaned the scan data to remove surface noise.
• Rebuilt the kit as parametric CAD with a reference geometry set taken from the body itself, rather than from the previous parts.
• Ran a DFM review on draft angle, wall thickness and the split lines required for the intended tooling.
• Vacuum cast a first-article set so the client could trial-fit before committing to steel tooling.

Result

All eight parts released to tooling with no geometry rework after first article. The customer reported that the wheel-arch interface, the original failure point, held within tolerance across the trial builds.