Case Study: Bloodhound SSC achieves rapid, accurate gearbox reverse-engineering for GT40 rebuild with 3D Systems

Rebuilding A Classic Car With 3D Scanning And Reverse Engineering from 3D Systems Geomagic

3D Systems Geomagic worked with engineer Brian Coombs — engineering lead for Bloodhound SSC and a hobbyist rebuilding a Ford GT40 replica — who faced a packaging and fitment challenge: he wanted to build a stronger gearbox using internal parts from an old Reynard race car but needed to verify that the assembled gearbox would fit, align, and not interfere with surrounding components in the car’s engine bay without spending days on physical mock-ups.

The team used a Solutionix Rexcan 420 scanner and automatic turntable to capture 72 scans, then processed the data with Solutionix ezScan and Geomagic to create a watertight NURBS surface model, identify geometry features, and export a STEP file into Siemens NX for volume-claim packaging. The near-automatic workflow produced an accurate, CAD-ready model in about two hours, saving significant time, ensuring proper fit and alignment, and giving Coombs the confidence to manufacture and install the new gearbox.

Bloodhound SSC

Brian Coombs

Engineering Lead for Mechanical Design