3D Printable Prototype CAD Design

Job Title: Reverse Engineering / Class-A Surface Designer – Two-Wheeler Body Panels (Scan-to-CAD)

Project Overview
We have 3D scan data (mesh) of the body panels of a Honda Activa 6G scooter. We need these converted into clean, editable CAD surfaces, then a redesigned outer skin built to a client’s design, while still fitting the existing chassis and neighbouring panels.

Scope of Work

Clean and prepare the scan mesh (noise removal, alignment, hole filling).
Rebuild accurate NURBS surfaces and solids from the mesh (scan-to-CAD), with deviation analysis against the scan.
Preserve all mating and mounting geometry exactly: clip points, screw bosses, panel edges, and gap/flush relationships with adjacent panels.
Redesign the outer visible surface to the client’s reference design [sketches / renders / reference images will be provided].
Check panel gaps, clearances, and continuity (G1/G2 where required).
Deliver the final CAD files and a deviation report.

Required Skills

Proven experience in scan-to-CAD reverse engineering of freeform/organic surfaces
Surfacing software: Rhino, Alias, CATIA, Geomagic Design X, QUICKSURFACE, or equivalent
Experience with automotive or two-wheeler body panels / plastic parts
Knowledge of plastic part design basics: draft angles, wall thickness, rib and clip features
Ability to work from scan data and 2D/3D design references

Nice to Have

Experience with injection-moulded parts (ABS/PP)
Prototyping experience (3D printing for fit checks)
Familiarity with Indian two-wheeler standards

Deliverables

STEP and IGES files (editable surfaces/solids)
Native CAD file [Rhino/Fusion/other]
STL of the redesigned panels for 3D printing
Deviation analysis report (target: within ±[0.5] mm on mating areas)

Inputs We Will Provide

3D scan mesh files [format: STL/OBJ/PLY]
Client design references
Key dimensions and chassis mounting information [if available]