Contact

Summary of this article

3D scanning enables the creation of precisely fitted packaging for products with complex geometries, vulnerable areas or limited CAD data. For high-tech, medical technology, defence and industrial manufacturing companies, this is strategically important: the fit of the interior largely determines whether valuable components remain securely and consistently protected during handling, storage and transport.

Manual measurement or design based on incomplete information increases the risk of excessive movement, pressure points and incorrect product securing. This can lead to transport damage, Dead-on-Arrival deliveries, rework, additional design iterations and delays in production or dispatch. Quality, delivery reliability and customer confidence may also come under pressure. At the same time, inaccurate designs result in unnecessary material use, higher costs and insufficient standardisation across the supply chain.

Faes uses 3D scanning to digitally capture product contours and critical areas and translate them into a dimensionally accurate packaging interior. This makes engineering, validation and repeat production easier to control. In this way, digital packaging development becomes a strategic tool for reducing risk, controlling costs and structurally improving operational performance.
Show full summary »

Flight case design is all about precision. Especially when working with fragile or complexly shaped equipment such as lamps, speakers or mixers. In many cases, we receive a 3D file from the client, a STEP file, with which we can get straight to work. But what if it's missing? Or if the shape of the product is so complex that manual measurement is no longer a reliable option?

To do this, we deploy advanced 3D scanning. With this technology, we digitally record the exact shape, dimensions and vulnerable zones of a product. This creates a highly accurate 3D model, which our engineers use as the basis for a perfectly fitting interior design and flight case. This not only ensures optimal protection, but also a faster design process, fewer errors and shorter lead times.

3D scanner in gebruik voor digitale modellering van maatwerk verpakking bij Faes

When do we choose 3D scanning?

We use 3D scanning in two situations. First, when no usable STEP file is available, for example for defence-related products or lighting equipment. Second, when an object is too complex to measure manually, such as products with hollow spaces, angled surfaces, or fragile components like lenses that must not be subjected to pressure.

Speed is another important factor. Because the scanning process itself is relatively quick, products do not need to remain at our facility for long. This is ideal for customers with limited loan periods or sensitive equipment.

In short, 3D scanning is the perfect solution when:

  • No STEP file is available
  • The object has complex geometry
  • Fragile areas must be accurately identified and avoided

How does the 3D scanning process work?

Once it is decided that we will deploy 3D scanning, we start with the careful preparation of the product and the scanning itself. The whole process takes place in several stages:

  1. Physical availability of the product
    The product is temporarily delivered to us, or we visit you on location. Ideally, the scanning will take place in our own environment, so we can immediately check that the data is complete.
  2. Multidimensional scan capture
    With an advanced 3D scanner, we capture the object from multiple angles. Often the product is placed in two or three different positions, so that even undersides, recesses and hard-to-reach areas are properly captured.
  3. Combining scans into one model
    The individual scans are combined into one complete 3D model. This is done in a so-called “project environment,” in which various orientations are combined into a conclusive digital image. The complete turnaround time of these first three steps averages 1.5 to 2 hours. With multiple objects in succession, this time is further reduced.
  4. Flight case and interior design
    Our engineers use the model as a basis to design an interior that perfectly matches the shape, position and vulnerable parts of the product. Here, we also take into account requirements such as buffering, bearing surfaces and “no touch” areas, as in the case of a lens or module that should not experience pressure.

What are the benefits of 3D scanning?

  1. Minimum time on site or at Faes
    With a 3D scan, we can fully digitally capture the product in a short time. This means that your product does not have to stay with us unnecessarily long. Especially for valuable or scarce equipment, this is a great advantage.
  2. No dependence on technical drawings
    Sometimes you simply do not have a 3D model of your product, or you are not allowed to share it due to NDAs or defense classifications, for example. In those cases, 3D scanning is the solution: we create the model ourselves.
  3. Perfect fit, even with complex shapes
    Where manual measurement falls short, 3D scanning provides a highly detailed model with millimeter accuracy. This allows us to design an interior and flight case that fits the exact contours of your product, including cutouts, corners and round shapes.
  4. Optimal protection of vulnerable parts
    Some parts should not come into contact with foam, such as lenses, connectors or moving parts. Thanks to the digital model, we know exactly where the product may or may not receive support. In this way, we minimize the risk of damage during transport.
  5. Higher first-time-right score
    An accurate 3D model means fewer revisions and error corrections in the design. We design faster and more accurately, which translates directly into a shorter turnaround time for your project.
  6. Acceleration of repeat orders
    We store the generated 3D model securely and it is immediately reusable for future orders or modifications. This makes the ordering process for repeat orders significantly faster and more efficient.

Why 3D scanning makes a difference

3D scanning offers a solution when the STEP file of a product is missing, or when the shape and fragility of the product require an extremely accurate approach. By digitally capturing a product, we create a conclusive 3D model that forms the basis for a flight case that fits exactly, down to the millimeter! This results not only in optimal protection, but also in a more efficient design process, shorter lead times and a lower error rate.

Whether it is high-end lighting, audio equipment or specialized technical products: with our 3D scanning solution, we are able to design a suitable case for any object, without depending on existing CAD files.

Wondering if 3D scanning could also do something for your product?

Have more questions about scanning, or want to know if we can scan and package your product? Feel free to contact us. We would love to think with you.

Print
Email Download PDF
Carlo Leijten

Carlo Leijten

Account Manager

Carlo Leijten is an account manager at Faes specializing in medical applications and audiovisual equipment. He helps customers in these plastics industries develop customized packaging solutions that meet stringent requirements for protection, cleanability and mobility.

More articles by Carlo Leijten

More about Custom Design & Production

4 pitfalls in the development of industrial packaging

Read article

How do you optimize case design for stackable storage?

Read article

How does a temperature test work for packaging that has to withstand extreme temperatures?

Read article

This is how we create the ideal packaging together

Good packaging doesn’t just happen by chance. Using a tried-and-tested approach, our specialists guide you step by step from the initial idea to the finished product.

Contact
1
Intake
During an initial consultation, our packaging experts will identify your specific requirements. By discussing the criteria the packaging must meet, they can work with our engineers to develop a concept.
2
Concept
Is standard packaging an option, or is bespoke packaging required? This decision is made in consultation with the consultants and designers
3
Design
Based on the concept, you will receive a suitable proposal. Thanks to our short lines of communication, we can easily make adjustments whenever necessary. Are you happy with the advice? If so, we’ll work towards producing a prototype.
4
Prototype
Throughout the process, we present concepts digitally and, where necessary, submit 2D drawings for review. You and your project team members can provide feedback or approve them, ensuring that decisions are clearly documented and the review process runs efficiently.
5
Production
Once approval has been given, our skilled craftsmen get to work on producing the packaging. From closures to a fully bespoke interior: we ensure that all your requirements are carefully incorporated into the final solution.
6
Service
We remain involved even after delivery. We are happy to take care of all your packaging needs, so that you can count on our support for maintenance, modifications or more complex issues.