Revolutionizing Custom Engine Fabrication with HandySCAN BLACK Elite & VXmodel

Centurion Performance & Engines is an Illinois-based manufacturer of custom performance engines and parts. It is also a custom tuning and install body shop in high demand.

Founded in 2009, the company has a research and development department equipped with an array of advanced tools, including a machining center with a SolidWorks station. This comprehensive setup enables the team to design and test the unique combinations of systems and parts that set their products apart, achieving levels of functionality never seen before. Many components and ideas tested here are subsequently integrated into other builds, driving continuous improvement and innovation for customers.

The challenge: Hand fabrication makes production scalability difficult

Centurion Performance & Engines prides itself on making superior-quality products for its discerning clientele. However, due to increasing demand and an uptick in the complexity of the components to be developed, the Centurion team realized that fabrication experts could no longer rely on manual processes alone.

The conventional fabrication processes were slow and difficult to replicate accurately, preventing team members from producing consistent, high-quality parts and assemblies. This was especially true when it came to implementing organic surfaces to design composite panels that mate properly together and create new power systems that could fit into existing engine compartments.

Moving from prototype to production was particularly challenging due to difficulties in visualizing the entire system, such as an engine bay, without a digital representation. This led to a lot of back-and-forth between teams and longer lead times.

Many innovative projects remained in the conceptual stage because the cost and time associated with manually developing the systems were prohibitive. Recognizing the importance of accurate equipment for successful prototype parts, Centurion Performance & Engines was motivated to explore more viable and efficient solutions.

“Having already worked with a customer on a reverse engineering project with a CMM, I knew that a metrology-based solution was key to developing successful prototypes,” explained Tim Slater, the company’s president. “Having seen 3D scanning technologies in action, it became very and immediately clear this was a direction we needed to go.”

The solution: HandySCAN BLACK Elite and VXmodel outperform in terms of 3D scanning accuracy and post-processing speed

Tim tested multiple 3D measurement products. “After much difficulty in post-processing scans, which led to inaccuracies in the data, and realizing how much time and effort was spent manipulating the scan so that I could complete a post-process to satisfaction, I decided to try the metrology-grade HandySCAN BLACK Elite,” he said. “It was a decision that came after a year and a half of frustration and lack of acceptable results.”

The engineering team were impressed with the results. “The accuracy of the raw 3D scans combined with the power of Creaform’s VXmodel post-processing software gave us the speed and extremely high-quality renderings we simply couldn’t get with the other equipment we tried. The ease of scanning is great, and the software is brilliant.”

Creaform’s technology transformed Centurion Performance & Engines’ time to market and production capacity. Using the HandySCAN BLACK Elite, teams could quickly and accurately scan components and existing engine compartments, allowing for precise design and integration of new power systems that met customers’ exacting standards. The ability to quickly create and test prototypes significantly reduced development time.

For instance, Tim was able to design, manufacture, and test a new part for their race team’s airplane within 48 hours—a process that traditionally would have taken much longer.

“After completing nearly two months of non-stop work modifying our race team’s first airplane, test flights were completed satisfactorily with three days remaining before needing to leave for the racing event. An area left unfinished was a large clearance hole that was cut in the bottom of the engine cowling to fit the new performance exhaust system,” he described.

“Knowing this large hole was a major drag contributor, I set out to create a part to close it off and direct the engine cooling air appropriately and efficiently out the bottom of the aircraft.  On a Tuesday afternoon, I scanned the bottom of the cowling and surrounding area. Then, I sat on the computer for a couple of hours processing the scan, designing the part, and then the mould to create the part.  At about 11 p.m., I was at our facility, piecing together the appropriate pieces of urethane tooling board to machine out the mould.  At about 5 a.m., the machining was complete. I returned late in the morning to prepare the mould for laying up the carbon fibre part. Once the part was laid up and in a vacuum bag, I set a timer for 24 hours. Thursday late morning, I removed the part from the mould and transported it to the aircraft for trimming and installation. The part was fitted, installed, exhaust extended, and heat shields in place by about 9 pm that evening after barely 2 days from the start of the project.”

The results: Greater production output and new market opportunities

Implementing HandySCAN BLACK Elite and VXmodel generated impactful business benefits for Centurion Performance & Engines.

Tim mentioned that “the ability to visualize and fit components digitally before fabrication saved a tremendous amount of time and energy. The ROI comes from the ability to produce and sell multiples of a part—with unbeatable accuracy—thanks to extremely high-quality scanning that results in excellent tooling.”

He emphasized the importance of counting on a 3D scanning solution with a powerful and integrated post-processing software module. “The capabilities of VXmodel are far and above others I have used. I see all sorts of pretty scans people make with inexpensive handheld scanners. Nevertheless, the ability to pull accurate and consistent data off of the scan is where VXmodel shines. Its surfacing tools and the ability to send the files and scans directly into SolidWorks is nothing short of phenomenal.”

Creaform’s 3D scanner and scan-to-CAD software also created additional market opportunities for Tim’s business, allowing it to offer new services and product applications that were previously not feasible. “Since we bought HandySCAN BLACK Elite and VXmodel, we’ve been off to the races,” Tim concluded. “I have the confidence in the 3Dscanner, data and software to tackle any development or prototype project!