Ferrari F40 Scale model 1:24
Reverse Engineering

This project focuses on the reverse engineering of a 1:24 scale Ferrari F40 model, starting from 3D scan data and progressing towards a fully reconstructed CAD geometry suitable for large-scale manufacturing The initial dataset consists of high-resolution scan data acquired from the physical scale model. The mesh is treated as a geometric reference rather than direct modelling input. Particular attention is given to surface quality, scan artefacts, and geometric inconsistencies typical of scaled models, which are evaluated prior to reconstruction.

The modelling process follows a hybrid Nurbs approach, combining curve-driven surface reconstruction with controlled interpretation of freeform geometry. Rather than replicating the mesh, the reconstruction focuses on restoring surface continuity, curvature behaviour, and overall geometric coherence in line with the original design intent of the vehicle. Critical body features such as panel transitions, aerodynamic surfaces, and characteristic design elements are rebuilt through structured surface modelling. Once completed, the CAD model is fully parametric and organised for downstream use. The geometry is then scaled from the original 1:24 model to a full-size representation of approximately 3 metres in length. This scaling process is managed within a controlled parametric environment, preserving proportions and surface integrity.

The final CAD model is exported in STEP format and prepared for large-format additive manufacturing.The geometry is segmented into printable sections, optimised for assembly and structural stability, enabling the production of a full-scale, 3-metre-long physical replica.