Digital to Physical
Modern coachbuilding, not mass production
The pipeline
From point cloud to painted steel
Six stages. Three are digital, one bridges, two are physical. Every part on every commission passes through all six.
- DigitalScanStructured light, 0.05 mm
- DigitalAI reconstructionIntent separated from damage
- DigitalCAD masterThe part as designed
- BridgePrinted toolingBucks, jigs, fixtures
- PhysicalHand-formedSteel, aluminium, leather, wood
- PhysicalVerifiedOverlaid on the original scan
01AI-assisted part recreation
The factory geometry, recovered
Original panels are never straight. They carry decades of dents, filler, shrinkage and hand repair, and the factory press tools that made them are long gone. Structured-light scanning captures the part as it is today at 0.05 mm resolution.
Our reconstruction model has been trained on the geometry of period Porsche panels: the characteristic radii, the way a 1973 fender crowns, the swage lines that define a 964. It separates the designer's intent from the damage and rebuilds the surface as it would have left the press.
The output is a CAD master. On our documented RS fender study, the finished steel part laid back over the original scan deviated by less than 0.4 mm across the entire surface.
- Structured-light scanning at 0.05 mm
- Intent separated from damage
- CAD master for every recreated part
- Deviation under 0.4 mm on finished steel
023D-printing workflow
Tooling by morning
From each CAD master we generate the tools a coachbuilder has always needed: hammer forms, wheeling bucks, body jigs, drill guides, check fixtures and interior trim patterns. Two large-format printers run overnight.
A pattern-maker once needed a month to carve a buck by eye from a drawing. Ours is printed in hours and is accurate to the factory geometry, not to an interpretation of it. That accuracy carries straight into the metal.
We hold one rule absolutely: printed polymers are tools, never parts. Nothing printed is painted, trimmed or fitted to the finished car.
- Hammer forms, bucks and jigs
- Check fixtures for verification
- Trim and upholstery patterns
- Printed tools, never printed car parts
03AI-guided coachbuilding
The old craft, guided by new certainty
Where automation improves consistency, we use it. Billet trim, dashboard inserts, wheel centres and brightwork are CNC-machined from the same digital master as the body. Robot-assisted positioning holds panels to the jig within tenths of a millimetre during fit-up.
Where the human hand is better, nothing replaces it. Steel and aluminium are wheeled and planished by a craftsman over the printed forms, lead-loaded at the seams, and metal-finished before paint. Hides are cut to digital patterns and stitched by hand.
The materials are those Porsche would have specified, or a better grade of them: steel, aluminium, semi-aniline leather, wool, walnut, glass and titanium. This is coachbuilding in the original sense of the word.
- CNC-machined billet from the master
- Robot-assisted fit-up, hand-finished panels
- Hand-stitched authentic interiors
- No composites, no kits, no shortcuts
Specification of certainty
Numbers we hold ourselves to
0.05 mm
Scan resolution on every original part
< 0.4 mm
Surface deviation of finished panels from the scan
1 : 1
Every tool derived directly from factory geometry
100%
Body panels in steel or aluminium, formed by hand
Digital twin
Full 3D model and part library delivered with every car
0
Printed or composite parts on the finished car
Materials we build with
- Steel
- Aluminium
- Semi-aniline leather
- Wool
- Walnut
- Glass
- Titanium
Where this is going
The digital coachbuilding roadmap
Metrology, surface reconstruction, CNC tooling and digital forming, each labelled as available today, integrated through partners, or in development. Built around the 1973 Carrera.
Questions
Asked by every owner
No. Printing is used exclusively for tooling: hammer forms, bucks, jigs, fixtures and patterns. Every part fitted to the car is made of the authentic material, steel, aluminium, leather, wool, wood, glass or titanium, formed or machined from the digital master.
Sonderwunsch
See the method applied to your car
Specify your 911 in the configurator. The digital twin starts the day the specification is signed.