Case Study: Richard Childress Racing achieves precise SB2 engine digital model for FEA and CFD analysis with 3D Systems

Richard Childress Racing Reverse Engineers Engine for Accurate Digital Analysis

Richard Childress Racing (RCR), a top NASCAR team, was asked by GM Racing to create the first accurate 3D digital model of the SB2 small-block engine — a complex cast part with no reliable 3D data, only incomplete 2D prints. The casting’s intricate geometry and undocumented changes in molds meant RCR needed a model that exactly matched the finished part to support credible CFD, FEA and digital-assembly work within tight manufacturing tolerances.

RCR partnered with ADC to scan the block and cores, then used Geomagic Wrap to turn point clouds into cleaned polygon and NURBS surfaces, importing eight assembled surface files into Pro/ENGINEER for final machining simulation and exporting an IGES for CATIA. The process produced a 90 MB model three times more accurate than casting tolerances (down to .010–.005"), saved months of manual modeling, and now enables reliable CFD, FEA, secondary-machining checks and the foundation for full digital engine and vehicle assemblies.

Richard Childress Racing

Clifton Kiziah

Senior Design Engineer