Skip to Content
Metrology-Grade Laser Scanning Reverse Engineering 3D Printing

ENGINEERED TO
EVOLVE.

We combine modern technologies to provide modern solutions to the Automotive & Motorsports Industry, from reproducing discontinued legacy parts to designing high-performance motorsport upgrades. With a combination of metrology-grade laser scanning, parametric CAD modeling, and industrial 3D printing, we can replicate, optimize and manufacture a wide range of automotive components.

// SCAN ACCURACY
±0.015 mm
// SCAN VOLUME
UP TO 2m3
// DESIGN INTEGRITY
OEM+
// PRINT MATERIALS
•TPU •NYLON •PPA-CF
01 // OPERATIONS

OUR CORE OPERATIONS

Our team is outfitted with the latest technology to support automotive enthusiasts, professional builders and racers. We transform physical limitations into digital assets and high-performance realities.

[ LASER 3D SCANNING ]

Blue Laser Scanning

Using non-contact optical blue-light scanners, we capture complete surface geometric data grids of components, complete engines, or entire chassis structures with extreme fidelity and high volumetric accuracy.

Point Cloud Resolution: Up to 0.05mm
Material: Virtually Any Solid*
[ REVERSE ENGINEERING ]

Parametric Modeling

We translate raw, uneditable scan data (Point Clouds or Meshes) into fully feature-based parametric CAD models (STEP) optimized for standard manufacturing processes.

Optimization: Flaw Redesign
Output: SolidWorks / Fusion STEP
[ FDM 3D PRINTING ]

Fused Deposition Modeling

Our in-house FDM 3D Printers can produce lightweight, strong or flexible parts for flexible ducts, structural braces, prototyping, interior pieces etc.

Materials: TPU, PA12-CF & PPA-CF
Thermal Limit: Stability up to 210°C*
[ SLM METAL 3D PRINTING ]

Selective Laser Melting

For the most demanding and robust applications, we leverage industry leading solutions for SLM Metal Printing. Ideal for highly complex geometries that require high strength, robustness and longevity under the harshest conditions.

Materials: 316L Stainless & Titanium TC4
Key Attributes: Strength, Heat Resistance
02 // WORKFLOW

THE DIGITAL PIPELINE

01
P1

Laser Capture

Components are secured and laser scanned to capture the raw Point Cloud Data.

02
P2

Refinement

Point Cloud is refined and used to generate a watertight Mesh. It can be immediately printed or stored in your asset library.

03
P3

Reverse Engineering

Engineers manually re-model every curve, adjusting wall thicknesses, apply optimization strategies, and correcting historical wear flaws.

04
P4

Physical Production

Components are produced in FDM composites or SLM-printed metals.

03 // FIELD ARCHIVES

CASE REGISTRY

// SHOWCASING REAL-WORLD SOLUTIONS
[ RECONSTRUCTED CAD VIEW ]
VEHICLE: PORSCHE 911 ST YEAR: 1972

Billet Magnesium Intake Manifold

Rebuilt from a cracked magnesium vintage core casting. Scanned, optimized for modern internal airflow patterns, and printed in structural Aluminum.

METROLOGY AISI10MG METAL
[ TOPOLOGY OPTIMIZED ]
VEHICLE: NISSAN SKYLINE GTR YEAR: 1999

Extinct Engine Bracket Assembly

OEM bracket was long discontinued. Captured mounting points from block face scan, designed custom lightened topology, and printed in Carbon Nylon.

SPACE ANALYSIS CARBON-ONYX
[ FEA STRESS ANALYSIS ]
VEHICLE: MCLAREN 720S YEAR: 2021

Suspension Cover Clearance Aero

Designed custom hyper-clear fluid aero elements. Scanned complete wheel well environment to execute custom absolute-clearance fitment.

FULL BAY SCAN TITANIUM HARDWARE

Submit Your Request

Fill out our intake form and our team will respond within one business day.

Contact Us

We'd love to hear from you! If you have any questions, feedback, or need assistance, please feel free to reach out to us using the contact details provided. Our team is here to help and will respond as soon as possible. Thank you for getting in touch!

Email

       info@madbullautodesign.com

 Call

       +1 868-745-0062

 WhatsApp

       +1 868-745-0062