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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 deploy 3D scanning in two situations. First, when there is no usable STEP file available, for example for defense-related products or lighting equipment. Second, when the object is too complex to measure manually, such as products with hollow spaces, inclined surfaces or fragile parts such as lenses that should not be loaded.

In addition, speed plays a role. Because the scanning itself is relatively fast, products don’t have to stay with us for long. This is ideal for customers with limited loan time or sensitive equipment.

In short: 3D scanning is the perfect solution if:

  • No step file is available
  • The object is geometrically complex
  • Vulnerable areas should be accurately 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.

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