How does scan-to-print work?
A technical guide to turning physical objects into production-ready 3D printed parts
Scan to print is a workflow that converts physical objects into printable 3D models using high fidelity 3D scanning, reverse engineering, and digital preparation. It is used to recreate legacy parts, manufacture replacements, and produce custom components without original CAD files.
Table of Contents
What Is Scan to Print?
Scan-to-print is the process of taking a physical object—often one with no existing digital design—and transforming it into a production-ready 3D printed part.
It is commonly used when:
- Original CAD files are missing or outdated
- Parts are no longer manufactured
- Components must fit precisely within existing assemblies
- A part needs to be modified, improved, or reproduced
Scan-to-print goes beyond simple scanning. It combines measurement-grade capture, reverse engineering, and design for additive manufacturing to ensure the final part performs as intended.
Step 1: Capturing the Physical Part (3D Scanning)
The process begins with high-fidelity 3D scanning, where the geometry of the physical part is captured as digital data.
3D Scanning Technologies Used
Structured light 3D scanners: structured light scanners project patterned light onto an object and measure how the pattern deforms across the surface. This method produces very high-resolution surface data and is ideal for capturing fine details, organic forms, and tight tolerances.
Laser 3D scanners: laser scanners use a laser line or point to measure geometry and are often used for larger parts, assemblies, or environments where structured light systems are impractical.
Photogrammetry: photogrammetry reconstructs 3D geometry from hundreds or thousands of photographs taken from multiple angles. While it is generally less precise than laser or structured light scanning, it excels at scale and accessibility.
What the Scan Produces
- Point clouds (raw spatial data)
- Mesh models (triangulated surfaces)
- Texture and color data (optional depending on scanner)
Accuracy is determined by scanner resolution, part size, surface condition, and alignment strategy. At this stage, the goal is to capture geometry as faithfully as possible.
→ Learn more about Kemperle Industries 3D Scanning Services
Step 2: Mesh Cleanup and Optimization
Raw scan data is rarely ready for printing without refinement.
This step includes:
- Removing noise and stray data
- Filling holes and gaps
- Correcting surface artifacts
- Ensuring the model is watertight
- Simplifying geometry where appropriate
In some cases, a cleaned mesh can be printed directly. In others, especially for functional or tolerance-critical parts, further engineering is required.
Step 3: Reverse Engineering to CAD
For functional parts, production components, or designs that need modification, the mesh is converted into a parametric CAD model through reverse engineering.
Why Reverse Engineering Matters
- Enables precise tolerances
- Allows dimensional edits
- Supports material substitution
- Enables long-term reuse of the model
- Creates manufacturing-ready geometry
Common techniques include surface reconstruction, feature recognition, and solid modeling from scanned geometry.
→ Learn more about Kemperle Industries Reverse Engineering Services
Step 4: Design Optimization for Additive Manufacturing
Once a CAD model exists, it must be optimized for the chosen 3D printing technology and material.
Typical considerations include:
- Wall thickness and reinforcement
- Fillets and stress relief
- Orientation planning
- Support strategy (if required)
- Tolerance adjustments
- Material-driven geometry changes
This step ensures the part is not just printable, but reliable in real-world use.
Step 5: Choosing the Right 3D Printing Technology
Scan-to-print workflows support multiple additive manufacturing processes. The final choice depends on strength, accuracy, material, and volume requirements.
Common options include:
- FDM (Fused Deposition Modeling), also known as FFF (Fused Filament Fabrication)
- SLA (Stereolithography)
- SLS (Selective Laser Sintering)
- MJF (Multi Jet Fusion)
- PolyJet
- DLSM (Direct Laser Metal Sintering)
→ Choosing the Right 3D Printing Technology: A Complete Comparison Guide
→ Explore Kemperle Industries 3D Printing Services
Step 6: Post-Processing and Validation
After printing, parts often require finishing and validation:
- Support removal or depowdering
- Heat treatment (for some materials)
- Machining or sanding
- Surface finishing
- Test fitting and functional validation
This ensures the printed part performs as intended in its final environment.
Common Scan-to-Print Use Cases
Scan-to-print is used across industries for:
- Replacement parts without CAD files
- Legacy industrial components
- Automotive restoration and customization
- Tooling and fixtures
- Marine and aerospace components
- Fine art, sculpture, and heritage preservation
Common Challenges
Scan-to-print often involves challenges such as:
- Reflective or transparent surfaces
- Worn or damaged originals
- Tight tolerance requirements
- Material substitution
- Scaling and fit accuracy
These challenges are solved through proper scanning strategy, engineering judgment, and iterative validation.
Can you 3D scan and print any object?
Most objects can be scanned and printed, but material, size, and surface properties may require specialized preparation or workflows.
How accurate is scan-to-print?
Accuracy depends on scanner resolution, part size, and engineering approach, but sub-millimeter accuracy is achievable in many cases.
→ More on 3D Scanning Accuracy and Resolution
Do I need CAD files to 3D print a part?
Not to start with. Scan-to-print workflows are specifically designed for situations where CAD files do not exist so creating them is part of the process.
Can scan-to-print be used for production parts?
Yes. With proper reverse engineering and material selection, scan-to-print can be used for end-use and low-volume production parts.
Start a Scan-to-Print Project
If you have a physical part that needs to be reproduced, improved, or manufactured, Kemperle Industries can guide you through the entire scan-to-print process—from capture to final fabrication.
