Case Study: Schooner Zodiac achieves accurate as-built CAD models and hull lines from 3D scans with 3D Systems' Geomagic Design X

Turning Tall Ship 3D Scan Data Into a CAD Model With 3D Systems Geomagic software

3D Systems worked with engineer Christian Stark to bring the 90‑year‑old schooner Zodiac into the digital age after original blueprints were lost and crew noticed asymmetrical sailing behavior and past repairs. The challenge was to accurately measure the real as‑built hull—both port and starboard—using massive 3D scan data and turn it into usable CAD drawings and models for analysis and restoration.

Using a FARO Focus scanner, Ross Nairn captured over 2 billion points (later reduced to ~26 million), and Christian processed the data in Geomagic Design X to clean, mesh, autofix and generate surfaces. Accuracy‑Analyzer and surface trimming produced precise hull, deck and transom models; exported 2D sections revealed the port hull was indented up to 3 inches. The resulting 3D CAD model supports updated certification and stability analysis, virtual walkthroughs, 3D printing and future restoration and design work.

Schooner Zodiac

Christian Stark

Engineer