24 September 2026
3D scanning the roof of a Suzuki Vitara to build a custom roof rack
A client wanted to fit a rooftop tent on their Suzuki Vitara. The usual problem with classic or modified vehicles is that off-the-shelf accessories never quite fit, so the company in charge of designing and building the roof rack needed something very specific: the real geometry of the roof, down to the millimetre. That is where we came in.
The challenge: measuring a roof that isn't flat
At first glance a roof looks like a simple surface, but it has ribs, curves, drip rails and support areas that cannot be measured properly with a tape measure. If the roof rack does not sit exactly where it should, you get gaps, noise or stress points on the bodywork.
The solution was to digitise the entire roof and deliver a 3D model the manufacturer could design on directly.
How we did it
The client brought the car to the car park at our office in Erandio (Bizkaia). We set up our mobile station right there: the scanner, a laptop in a case on a tripod and a portable battery, with no need for a power outlet. It is the same kit we take with us when we travel to a workshop or an industrial unit.
1. Preparation with targets. We placed adhesive dots and magnetic targets on the roof and sides. They act as references so the scanner always knows where it is and can stitch all the captures together accurately. They are removed afterwards without leaving a mark.
2. Scanning with the HandySCAN MAX. We used the Creaform HandySCAN MAX, our blue-laser scanner for large parts (from 1 to 10 metres). Scanning the whole roof took just over an hour.
3. Processing at the office. Back at the office, we cleaned, aligned and generated the final mesh of the roof.
Two technical details we are often asked about
Do you need matting spray on metallic paint? Not in this case. The car had metallic paint and the scanner read it without any preparation.
What about the windows? This is where you need to be careful: the laser passes through glass and captures whatever is behind it. On screen, the steering wheel and seats even showed up through the windscreen. For this job we only needed the roof, so it was not a problem. But if the geometry of the windows is needed, we apply a temporary matting spray that is easily removed.
The result
We delivered the model in STL format directly to the company that designs and builds the roof rack. With it, they can design the mounts on the real shape of the roof, without taking measurements by hand or doing trial fittings.
Do you have a similar project?
We scan roofs, bodywork and vehicle parts for roof racks, rooftop tents, spoilers, camper conversions or any custom accessory. You can bring the vehicle to our office in Erandio or we come to you, with self-contained equipment, at your workshop or industrial unit in Bizkaia, the Basque Country or anywhere else in Spain.