How 3D Metrology Solutions helped Bentley produce exact replicas of the Bentley Speed 6

The 1930s Bentley Speed 6 is a classic automobile, renowned for its engineering excellence, performance, and historical significance. We undertook a project to perform reverse engineering, along with a complete scan, on an original model. The goal was to produce a limited number of exact replicas of the original Bentley Speed 6. A critical constraint of the project, which would be our main challenge, was that the original car could not be dismantled.

This case study details the methodologies, challenges, and outcomes as 3D Metrology Solutions supported Bentley on this project.

Project objectives

These were our objectives:

• Provide accurate digital models for the customer to be able to produce an exact replica of the original car.

• Ensure each reproduced part matches the original in every detail.

• Maintain the historical integrity and authenticity of the reproduced vehicles.

Project scope

The scope of the project included:

• Preparation and planning: Detailed research and setup for non-invasive scanning.

• 3D Scanning: Comprehensive scanning of the Bentley Speed 6.

• Data processing: Converting scan data into detailed CAD models.
  
  

Methodology

Preparation and planning

The project began with meticulous planning, including:

• Research: Extensive research was conducted to understand the historical context and original specifications of the Bentley Speed 6.

• Selection of equipment: High-precision, non-invasive metrology equipment was selected, including the AS1 scanner with an AT960 Laser Tracker and a Romer arm.
  

3D Scanning

The scanning process involved several steps:

• Surface preparation: We ensured that all visible surfaces were clean and free of debris.

• Scanning setup: Setting up the AS1, Laser Tracker & Romer Arm in a controlled environment, to minimise data distortion.

• AS1 Scanner and AT960 Laser Tracker: Deploying the AS1 scanner AT960 for high-precision scanning of the vehicle’s geometry.

• Romer arm: Employing the Romer Arm for detailed, high-resolution capture of intricate parts and internal geometries.
  

Data processing

The raw data from the scans required processing to create accurate digital models:

• Point Cloud generation: The initial output from the scanners was a point cloud representing the surface geometry.

• Mesh generation: The point cloud was converted into a mesh model, creating a continuous surface.

• CAD modelling: The mesh models were then used to create precise CAD models, ensuring all geometric details were preserved.

• Validation: We compared CAD models with historical blueprints and physical measurements, to ensure accuracy.
  
  

Challenges and solutions

These were the challenges we faced and how we resolved them. 

Non-invasive scanning

• Challenge: Scanning the vehicle without disassembly.

• Solution: Employing non-invasive scanning equipment, including the AS1 scanner with AT960 Laser Tracker & Romer arm.
  

Accuracy of scans

• Challenge: Achieving high accuracy in the scans to ensure faithful reproduction.

• Solution: Calibration of scanning equipment before each session, cross-referencing with known dimensions from blueprints. Multiple scans were taken from different angles to capture complete geometry.
  

Data processing complexity

• Challenge: Processing large volumes of scan data to create accurate models.

• Solution: Utilising powerful computer hardware and specialised software, we chose Polyworks for Point Cloud processing and mesh generation. Redundant data was filtered out to streamline the process.
  

Outcomes

The project resulted in several significant positive outcomes:

• Accurate digital models: High-precision CAD models of the Bentley Speed 6, ensuring all geometric details were captured.
  

• Successful reproduction: A limited number of exact replicas of the Bentley Speed 6 were produced, each matching the original in every detail.
  

• Preserved heritage: The reproduction project ensured the preservation of an iconic piece of automation history.
  

Conclusion

Reverse engineering and 3D scanning the 1930’s Bentley Speed 6 was a complex yet rewarding project. Without dismantling the original car, it wasn’t straightforward. We combined historical research, advanced technology, and meticulous craftsmanship to preserve and reproduce an iconic vehicle.

With the expertise of the 3D Metrology Solutions team, we achieved the project’s primary objectives. Our work contributed valuable knowledge and resources to the field of automotive restoration and historical preservation.