Karbonius Composites specializes in manufacturing precision moulds and composite components across various sectors, including automotive restoration and high-performance customization. Founded in 2008 in La Coruña, Spain, the company handles every stage of premium carbon fibre production—from design and engineering to manufacturing structural parts, decorative elements, and panels.
Karbonius Composites, renowned for precision and detail, supports high-end restorations and custom automotive projects, establishing itself as a leader in composite manufacturing.
As Jacobo Forjan, Engineer at Karbonius Composites explained: “Our clients expect nothing short of perfection. Indeed, any deviation compromises both the aesthetic and functional integrity of the parts. Moreover, our TÜV Rheinland certification for ‘Design and Manufacturing of Composites for the Automotive Sector,’ coupled with our rigorous internal traceability protocols, assures customers they’re receiving unmatched expertise and consistent support at every step.”
Navigating the Limits of Traditional 3D Measurements and Intricate Car Assemblies
Similarly, the Karbonius Composites team often faced challenges in accurately replicating complex vehicle parts, especially for classic car restorations. Traditional 3D measurement methods were painstakingly slow, often inaccurate, and incapable of capturing intricate geometries and organic curves. Consequently, manual measurements consumed hours of labor but often led to errors, waste, rework, and compromised aesthetics and fit
“We were using manual techniques that just weren’t up to the task,” said Jacobo. “Complex curves and fine details were nearly impossible to capture with the level of accuracy we required. This inevitably led to extensive re-engineering and delays, something our projects couldn’t afford.”
Ultimately, the defining moment occurred during a high-profile project that involved replicating a side fin for a coveted classic sports car. Ensuring a perfect fit was critical; any discrepancy would compromise both the part’s visual integrity and performance. At this moment, it became clear that Karbonius required a superior approach to 3D measurements.
The team at Karbonius Composites can scan vehicle assemblies on the shop floor easily using a HandySCAN 3D|BLACK Series 3D scanner
Implementing Advanced 3D Scanning Technology for Composite Manufacturing
Karbonius Composites’ experts identified critical requirements for an ideal 3D scanning solution, including:
- High accuracy and repeatability.
- 3D scanning speed.
- Portability to work directly on vehicles.
- Integration with reverse engineering software.
- Reliable technical support.
- An acceptable learning curve for the team.
Creaform’s metrology-grade HandySCAN 3D, along with its Scan-to-CAD and Inspection software modules, immediately stood out for the ability to precisely capture parts of any size, shape, material and surface type. The 3D scanner’s accuracy of 0.025 mm and robust design generated reliable and repeatable results, even in the demanding environment of the company’s shop floor.
As part of Creaform’s Metrology Suite™, the Scan-to-CAD module refined mesh data and prepared high-resolution 3D scans for reverse engineering, enabling the team to clean, align, and convert scans into precise parametric models ready for export to Karbonius Composites’ CAD software.
“The interface was very intuitive, and that helped a lot. As a result, we were able to export CAD files fully compatible with our design workflow, which made our work so much easier,” Jacobo mentioned.
Integrated 3D scanning software modules help designers and engineers refine, reverse engineer and inspect vehicle components
Scan-to-CAD helps to refine mesh data and streamlines 3D scans for 3D printing. Furthermore, it enables engineers and designers to seamlessly integrate scanned data into reverse engineering and product development. The Inspection module is a user-friendly tool for conducting part inspections and generating reports to meet engineering requirements.
The team was up and running in no time. With support from Creaform’s technical team, Karbonius Composites had the 3D scanner and software running within a week. Thanks to its user-friendly interface and training, the team quickly became confident and productive.
“The ease of integration surprised us. The impact on the team’s performance was remarkable. Design times were slashed by over 40%, errors from manual 3D measurements were virtually eliminated, and efficiency among the technical team improved,” said Jacobo.
Tangible Boosts to Accuracy, Productivity, and ROI
The introduction of Creaform’s technologies immediately transformed Karbonius Composites’ product development, particularly through a key project involving the reproduction of the classic car’s side fin. By 3D scanning the original part, Karbonius Composites quickly generated an accurate, high-resolution CAD model from which precise moulds and final carbon fibre components were produced. This ensured an impeccable fit, significantly reducing the risk of costly revisions.
The precision of the 3D scans substantially reduced the number of iterations required for moulds, accelerating validation and production stages. Financially, the system demonstrated an exceptional return on investment (ROI), fully paying for itself within the first year of implementation through time savings and reduced material waste.
“Creaform’s 3D scanning has fundamentally transformed how we operate. It’s no longer just a tool; it’s an integral part of our production process,” Jacobo added.
In the future, Karbonius plans to further leverage Creaform’s technology across a range of ambitious projects. These initiatives include scanning entire vehicles for custom aerodynamic packages, digitizing rare components for restoration purposes, and automating quality control processes.
“With Creaform, we’re confident to take on bigger, more complex projects. This technology has opened new opportunities we once thought were beyond our reach. Thanks to Creaform’s 3D scanning solutions, we can now deliver carbon fibre parts that set a new standard for quality and performance.”
TWA 3D presents to provide convenience and the quickest solution in the manufacture of prototype and reverse engineering, inspection & portable CMM, empowering our customer to create with confidence.
