Case Study: General Motors (GM Daewoo) accelerates die duplication—cuts tryout time by 30% (five weeks) with 3D Systems' Geomagic Design X

GM Daewoo Accelerates Die Duplication Using Geomagic Design X

GM Daewoo (now part of General Motors) faced a costly, time-consuming challenge: duplicating handworked stamping dies for a new Aveo production facility in Poland. Because on‑die adjustments made the as‑built tooling differ from original CAD, each duplicate required a full multi‑week tryout—delaying production and increasing costs across more than 25 large die sets.

The team implemented dense 3D scanning (CogniTens Optigo) and Geomagic Design X scan‑to‑CAD to convert point clouds into parametric, machinable CAD models that capture as‑built modifications. This eliminated repeated tryouts, cutting tryout time by five weeks (about 30%), yielding an estimated $200,000 saving for the tailgate die and roughly $5 million across the Aveo program, while delivering accurate, production‑ready duplicate dies.

General Motors