When an original RV accessory is damaged, discontinued, or hard to source individually, are you limited to finding a substitute or buying an entire assembly?

For RV owners who enjoy DIY modifications, 3D scanning and 3D printing offer another approach: scan the existing part to capture its true geometry, adjust the model in CAD software, and then turn the design into a physical replacement.

In this case, Canadian RV creator The Trio In Transit (with over 730,000 followers on Instagram) used the 3DeVOK MT professional 3D scanner for automotive customization to scan the original charging-port base of their RV, imported the data into Fusion 360 to adjust the mounting structure, and finally produced a 1:1 replacement part through 3D printing.

For modification projects where ready-made replacement parts are hard to find, this object-first digital workflow opens up a new option for part replication and custom manufacturing.

Case Video: From 3D Scanning the Original Part to Making the Replacement

When the original accessory is difficult to purchase on its own, can you redesign and produce a replacement based on the existing part?

The Trio In Transit demonstrates the full process, from 3D scanning the original component and processing the data, to CAD design, 3D printing, and installation.

Watch the case study video:

Step 1: Capture the Original Charging-Port Part with the 3DeVOK MT Professional 3D Scanner

The first step in part replication is to obtain the 3D geometric information of the original component.

Traditional manual measurement usually records external dimensions, hole positions, and local structures. For parts with curved surfaces, edge profiles, and multiple mounting holes, a few dimensions alone may not fully reconstruct their geometry.

In this case, the creator used the 3DeVOK MT handheld professional 3D scanner to scan the original charging-port base, capturing data from both the front and back sides to lay the groundwork for subsequent model processing and design.

The key aspects of this step include:

• Capture the part's true shape: obtain the surface geometry of the original component, preserving the contour information needed for design.
• Record mounting-related structures: provide a reference for processing hole positions and structural dimensions later.
• Establish a foundation for digital replication: convert the physical part into 3D data, reducing the effort of rebuilding the model entirely from manual measurement.

For small replacement accessories that need to be replicated, scanning is valuable not only for recording the shape, but also for providing a more intuitive geometric reference for later CAD design.

Step 2: Merge Scan Data to Prepare for CAD Design

Because the front and back structures of a part cannot be fully captured from a single viewpoint, the data collected from different directions must be processed and integrated.

After 3D scanning, the creator used 3DeVOK Studio scanning software to process and merge the front-and-back data, then imported the processed model into Fusion 360.

The entire data-processing workflow can be summarized as:

3D scan, process and merge scan data, generate a complete 3D model, import into CAD software.

The scanned model provides an original geometric reference for subsequent design, helping preserve the basic contour of the original part and modify the structures that need adjustment.

Note that scan data typically exists as a mesh model and is not equivalent to a directly editable parametric CAD model. Depending on the model format and design requirements, mesh repair, simplification, or other data processing may also be needed.

Step 3: Adjust Mounting Holes in Fusion 360

After obtaining a complete 3D model, the next step is to adjust the design according to actual installation needs.

In this case, the creator imported the processed scan model into Fusion 360 and adjusted the mounting holes at the four corners of the replacement part, refining the model for 3D printing.

This process reflects the division of labor between 3D scanning and CAD design:

• High-precision 3D scanning: captures the geometry of the original component.
• Fusion 360: uses the scan model as a reference to adjust mounting holes and related design details.
• Pre-print check: confirm before printing that the model structure meets expected manufacturing and assembly requirements.

For replacement parts that must fit existing RV structures, mounting-hole positions, edge contours, and overall dimensions can all affect the final assembly result. Therefore, capturing the original part's 3D data first and then designing for it provides a clearer workflow for part replication.

Step 4: Produce the 1:1 Replacement Part with Resin (SLA) 3D Printing

After finalizing the model, the creator used a UniFormation resin 3D printer to produce the 1:1 replacement part corresponding to the original component.

After printing, the resin part was post-cured with UV light so the resin fully hardened and reached the expected rigidity and mechanical performance, preparing it for installation and fitting.

Compared with designing entirely from scratch, using the original part's scan data as a reference helps the designer preserve the geometric features that need to match, then adjust the mounting structure according to actual needs.

This workflow suits projects where some original accessories are hard to source, a specific shape needs to be replicated, or existing structures need custom modification. However, whether a replacement is suitable for long-term use also depends on the resin material, part structure, ambient temperature, and actual load conditions. Reliability cannot be judged solely by similar appearance or matching dimensions.

Step 5: Install the Replacement and Verify the Actual Fit

For a part-replication project, printing is not the finish line. Whether the replacement installs correctly and matches the surrounding structures matters just as much.

After mounting the printed part in place, you can focus on checking:

1. Shape match: does the replacement's overall contour match the original mounting area?
2. Hole accuracy: are the mounting holes aligned with the corresponding fixed positions?
3. Fastening: is the part secure after installation, with no obvious looseness?
4. Structural interference: does the replacement affect the normal installation and use of surrounding components?
5. Actual use requirements: evaluate material strength, heat resistance, and other necessary properties based on the part's purpose.

If trial assembly reveals unsuitable hole positions or local contours, you can return to Fusion 360 to modify the model, print again, and re-verify.

This forms an iterable part-replication workflow: 3D scan, data processing and merging, CAD design, 3D printing, installation and fitting.

This is also one of the core values of combining 3D scanning with 3D printing: converting a physical part into a model that can be processed and modified in a digital environment, then verifying the design result through manufacturing and fit checks.

Why RV Parts Replication Needs 3D Scanning

The Trio In Transit case shows the value of 3D scanning in RV DIY modification and custom replacement-part production. For similar projects, 3D scanning can mainly contribute in the following ways.

An alternative path when original accessories are hard to source

For components where ready-made replacements are not easily found, you can scan the existing part to capture geometry, then combine CAD design and 3D printing to produce a replacement. Whether replication is appropriate still depends on the original part's condition, design requirements, and intended use.

Complex contours and mounting holes are easier to digitize

A scanned model provides more comprehensive geometric reference than a few manual dimensions, making it easier for designers to view the original contour in CAD software and adjust the structures that need modification.

Supports single-piece customization and design iteration

RV modifications often involve non-standard parts, and requirements can vary by vehicle model, modification plan, or installation space. Adjusting through a digital model and then printing a physical part for verification supports small-batch or single-piece custom development.

Reduces work that fully depends on manual measurement

Scan data helps designers build a 3D reference model of the original part, reducing the work of rebuilding geometry from scratch. But final dimensions and assembly results still need confirmation against scan quality, model processing, and actual installation.

3DeVOK MT: 3D Data Support for RV Parts Replication

In this workflow, the 3DeVOK MT professional 3D scanner handles front-end 3D data capture, providing the foundation for subsequent CAD design and replacement manufacturing.

Its main features include:

• Multiple scanning modes: 3DeVOK MT is equipped with 34-line blue laser, 22-line infrared laser, and infrared speckle modes, so you can choose the right method based on the part's shape, surface characteristics, and scanning task.
• Fine geometric data capture: up to 0.04 mm accuracy, supporting digitization tasks that need to record part details. Actual scan results are affected by factors such as workpiece surface, operation method, and site conditions.
• Supports digitization of various custom parts: can be used for RV accessories, automotive components, complex structural parts, and other objects that require 3D geometric data.

From scanning the original part, to adjusting the model in Fusion 360, to 3D printing and installation verification, the 3DeVOK MT provides the physical-data foundation for the entire digital workflow, helping users turn hard-to-source accessories into digital models ready for further design and manufacturing.

Learn more about the product: 3DeVOK MT Professional 3D Scanner for automotive customization

Frequently Asked Questions (FAQ)

Q1: If the original RV accessory is lost, can I remake it with 3D scanning?

If you still have an original part for reference, or can scan the relevant mounting area, you can use 3D scanning to capture geometry, then combine CAD design and 3D printing to produce a replacement. Whether replication succeeds depends on whether the original data is complete, whether the part structure is suitable for printing, and the actual use requirements.

Q2: Can the model from 3D scanning be used directly for 3D printing?

Not necessarily. Scan data usually needs processing to check model completeness, mesh quality, and dimensions, then necessary model repair or design adjustment based on the printing process. Details such as mounting holes, wall thickness, and fixing structures also need confirmation before printing.

Q3: Can Fusion 360 process 3D scan data?

Fusion 360 can import and process some scanned mesh data and carry out related design work. The specific operation depends on the data format, mesh complexity, and the software functions used. For parts that need parametric editing, additional mesh processing or geometry reconstruction steps may be required.

Q4: Can 3D-printed RV replacement parts be put into use directly?

It depends on the part's purpose. For non-load-bearing, low-risk appearance or fixing accessories, you can first check dimensions and structure through trial assembly. For components involving electrical connections, heat resistance, load-bearing, or other safety requirements, you need to further evaluate material and structural performance and perform necessary safety verification.

Conclusion: Give Hard-to-Source Parts a New Manufacturing Path

From scanning the original charging-port base, to adjusting mounting holes in Fusion 360, to 3D printing a 1:1 replacement, The Trio In Transit case shows how 3D scanning helps RV modification enthusiasts carry out part replication and custom manufacturing.

For RV, camper, and car DIY modification projects, 3D scanning can turn existing parts into digital geometric references, then combine with CAD design and 3D printing to unlock more possibilities for developing non-standard accessories.

Looking for a solution to replicate or customize RV parts?

Learn about 3DeVOK 3D scanning technology and explore the workflow from physical scanning and digital design to 3D printing.

Contact the 3DeVOK team

About 3DeVOK & SCANOLOGY

SCANOLOGY is a leading metrology brand delivering high-precision 3D measurement solutions for modern manufacturing and engineering. With over 10 years of expertise, six pioneering technological innovations, and customers in more than 70 countries, SCANOLOGY became the first publicly listed company in China's 3D scanning industry in 2025. Its solutions serve industries including aerospace, automotive, heavy equipment, additive manufacturing, and cultural heritage preservation, supporting major projects such as the China Space Station, China’s C919 passenger aircraft, and the China–Egypt joint archaeological program.

3DeVOK, a brand of SCANOLOGY, focuses on professional 3D scanners for applications including automotive customization, medical rehabilitation, museum and cultural heritage digitization, education and research, art and design, and maker projects. Committed to making professional 3D scanning easier and more accessible, 3DeVOK empowers users to bring their ideas to life.