Skip to main content
Introduction
Designing and manufacturing a hypercar in less than a year would have been unthinkable a decade ago. Now, thanks to advances in engineering, in particular 3D scanning, that’s exactly what RML Group has achieved with the launch of the GT Hypercar.
GT Hypercar was a project that required a rapid turnaround time. It’s the sort of challenge on which the total engineering solutions company thrives, thanks to its motorsport heritage and agile, innovative approach to projects.
With a group history that includes multiple championship-winning touring cars, one-off sportscars, high-specification resto-mods and low-volume performance vehicles, RML Group’s Bespoke division leverages in-house capabilities as well as working with key technical partners to produce exceptional results, not least on the GT Hypercar – RML’s “ultimate GT”.
The Big Idea
Codenamed P39, RML Group’s 39th whole vehicle project, the GT Hypercar was designed to showcase the Wellingborough team’s capabilities in an advanced, high-performance vehicle. The brief was to transform the class-leading 992-generation Porsche 911 Turbo S into a 900bhp ultra-lightweight machine; purpose-built for the track but comfortable to use on the road.
It called for RML Group to put its own stamp on a vehicle that retained a core of Porsche’s engineering DNA, producing a significant upgrade to overall driving dynamics.
The engineering team set out to completely reimagine the car’s key components, with control required at every stage of development, from data capture and design to validation and final assembly. Engineering and performance plans included:
- A full carbon fibre body conversion
- Custom aerodynamic architecture with active elements
- Reengineered suspension geometry and hydraulic systems
- A fully uprated powertrain with turbo and exhaust enhancements
To achieve this, RML needed a workflow that was digitally integrated from the outset – fast, precise, and enabling seamless feedback loops between design, fabrication and testing. This required full oversight over all stages of measurement, modelling, and validation, without relying on third-party services.
Empowering 3D Data
To support a seamless transition from reverse engineering to final inspection, RML used the Creaform MetraSCAN 3D, a high-resolution portable laser scanner known for its accuracy, speed, and ability to handle complex surfaces without preparation. Powered by VXelements, Creaform’s real-time 3D data acquisition platform, this system formed the backbone of RML’s scanning workflow across all P39 development phases.
Reverse engineering and concept development
The first phase involved digitally capturing the original Porsche 911 Turbo S to form the baseline geometry for the project. This process ensured every aspect of the vehicle could be reengineered with precision, without relying on legacy drawings or guesswork.
A donor 992-generation 911 Turbo S was fully digitised, including engine bay, chassis, wheel arches, and interior components. Scan data formed the base layer for CAD modelling, enabling the team to map out spatial constraints and plan component packaging.
Chassis and suspension redesign
To accommodate wider track widths, updated suspension geometry, and a new hydraulic ride-height system, the team needed to digitally validate every key interface. Scanning allowed for rapid redesign and integration of bespoke components.
Suspension mounting points and new track widths were scanned and validated to support bespoke uprights and height-adjustable hydraulic systems. This data enabled RML to evaluate geometry changes in CAD with full confidence in dimensional accuracy.
Body and aero engineering
As RML developed custom carbon fibre body panels and aerodynamic features, it was critical to ensure the physical output precisely matched digital models. Scanning was used to inspect both static and active aero components during mock-up and final fit. Full-size carbon fibre panels were inspected to check conformity against digital designs. Active aerodynamic elements, including deployable spoilers and underbody channels, were aligned precisely using scan references.
Powertrain development
The heavily upgraded engine and exhaust systems introduced new space and fitment constraints. By scanning each component post-machining, the team could immediately verify tolerances and integration before assembly. Custom manifolds, turbo housings, and exhaust components were scanned post-machining to verify fit and tolerance stack-ups. The resulting data allowed engineers to confirm part fitment and eliminate errors before installation.
Simulation and digital validation
Digital simulation played a key role in evaluating structural integrity, handling dynamics and aerodynamic performance. Feeding highly accurate scan data into simulation software allowed RML to test and validate concepts before committing to physical prototypes. Scan data fed into CFD and FEA tools to validate aerodynamic behaviour and structural integrity. This shortened the loop between physical prototyping and virtual refinement.
Fabrication and assembly
RML’s workshop teams rely on precise dimensional feedback during fabrication to ensure parts meet specifications without costly rework. With a scan-to-build approach, real-time inspection verified every key interface before final fit.
In-house fabricated parts were checked against digital references to ensure brackets, mounts, and panels met tight tolerances. This helped avoid rework and ensured assemblies progressed smoothly and efficiently.
On-track validation and final inspection
Before final dynamic testing, the vehicle underwent a full inspection to confirm geometry, fitment, and alignment. This final quality gate ensured that nothing was left to chance when the car was put through its paces at high-speed events.
Final dimensional checks confirmed alignment and panel fit before debuting the car at Supercar Fest, where it completed high-speed testing.
Technical Challenges
While RML has decades of experience in high-performance vehicle development, the GT Hypercar project introduced a unique set of technical and operational challenges. These included working with diverse materials, integrating bespoke systems and maintaining tight tolerances throughout a fast-moving development cycle.
This included:
- Complex, multi-surface reverse engineering of an already tightly packaged production car
- High-mix, low-volume part manufacturing, requiring exact fit without mass-production tooling
- Material diversity, from reflective carbon fibre to dark engine bay surfaces and painted metal
- Rapid development timelines, where iterative validation was essential to avoid production bottlenecks
Traditional measuring tools like hand gauges or fixed CMMs were either too slow, limited in mobility, or unable to handle surface conditions and the scale required.
Scanning Capabilities
To meet these challenges, RML turned to trusted technology. Having previously used Creaform on heritage builds and motorsport projects, familiarity with the system offered the flexibility, accuracy and portability required.
The MetraSCAN’s ability to scan complex geometry without surface preparation was a critical asset. Its performance on dark, glossy or reflective surfaces allowed engineers to quickly scan parts like carbon fibre body panels, polished manifolds and suspension arms without altering their surfaces or adding markers.
VXelements software integrates with CAD tools, ensuring accurate data handling and streamlined mesh processing throughout the project.
By incorporating 3D scanning tools directly into the workflow, RML achieved new levels of precision and agility in their build process. The benefits extended across design, engineering, fabrication and quality control. This digital-first approach allowed RML to treat the MetraSCAN as a core engineering tool, not just a quality control device.
Digital Transformation
With 3D scanning fully integrated into the engineering strategy, RML has redefined what’s possible in low-volume, high-performance automotive development. The P39 project marked a turning point in digital transformation.
- Full 3D scanning is now embedded across RML’s vehicle development lifecycle.
- Measurement-driven workflows enabled faster prototyping and higher consistency.
- Tools are now routinely used across RML operations.
- RML has proven that high-spec, low-volume engineering doesn’t need to sacrifice quality, efficiency or design freedom if the right digital tools are in place.
James Nurse, Senior Mechanical Design Engineer at RML Group, said:
“MetraSCAN has become an integral part of our workflow. It’s used in nearly every phase, from reverse engineering to inspection, and has far exceeded our expectations in terms of flexibility and performance.”
GT Hypercar has demonstrated what can be achieved when advanced 3D measurement tools are embedded at the heart of vehicle development. Supported by Measurement Solutions Ltd, RML delivered a bespoke, high-performance re-engineering of a modern classic, with millimetric precision, maximum control, and minimal compromise.
Today, the MetraSCAN 3D system is a vital part of RML’s engineering DNA, enabling them to push the boundaries of what’s possible in precision automotive innovation.
In Summary
The RML GT Hypercar project stands as a benchmark for what’s possible when cutting-edge measurement technology meets visionary engineering. Through the seamless integration of Creaform’s MetraSCAN 3D system, supported by Measurement Solutions’ expertise, RML achieved the precision, speed, and design freedom required to deliver an extraordinary vehicle.
At MSL, we’re proud to partner with innovators like RML Group who push the boundaries of performance and precision. Their success demonstrates how adopting a fully digital, measurement-driven workflow can transform even the most complex engineering challenges into world-class results.
Ready to accelerate your next project?
Explore how MSL’s 3D scanning and metrology solutions can help you take full control of your engineering process, from concept to final inspection.
