Karbonius Composites specializes in manufacturing precision molds and composite components across various sectors, including automotive restoration and high-performance customization. Founded in 2008 and based in La Coruña, Spain, the company’s production capabilities cover every step needed to deliver premium carbon fiber components—from initial design and engineering to manufacturing structural parts, decorative elements, sandwich panels, and beyond.

Known for its meticulous attention to detail, Karbonius serves clients that require parts with exceptional geometric fidelity and aesthetic precision. By working closely with high-end restorations and automotive customizations, the team is committed to excellence and valued as a leader in composite materials manufacturing.

Jacobo Forjan, an engineer at Karbonius, says, “Our clients expect nothing short of perfection. Any deviation compromises both the aesthetic and functional integrity of the parts. Our TÜV Rheinland certification for ‘Design and Manufacturing of Composites for the Automotive Sector,’ coupled with our rigorous internal traceability protocols, assures customers they’re receiving unmatched expertise and consistent support at every step.”

Navigating the limits of traditional 3D measurements and intricate car assemblies

The Karbonius team was consistently faced with 3D measurement challenges when replicating complex vehicle parts accurately, particularly for classic car restorations. Traditional 3D measurement methods were painstakingly slow, often inaccurate, and incapable of capturing intricate geometries and organic curves. Manual measurements required countless hours of labor, yet frequently resulted in errors, material waste, costly rework, and potential compromise of the part’s final aesthetics and fit.

“We were using manual techniques that just weren’t up to the task,” says Forjan. “Complex curves and fine details were nearly impossible to capture with the level of accuracy we required. This inevitably led to extensive reengineering and delays, something our projects couldn’t afford.”

The defining moment occurred during a high-profile project that involved replicating a side fin for a coveted classic sports car. Ensuring a perfect fit was critical; any discrepancy would compromise both the part’s visual integrity and performance. At that moment, it became clear that Karbonius required a superior approach to 3D measurements.

The team at Karbonius Composites can scan vehicle assemblies on the shop floor easily using a HandySCAN 3D|BLACK Series 3D scanner.

Implementing advanced 3D scanning technology for composite manufacturing

Karbonius’ experts identified critical requirements for an ideal 3D scanning solution, including:
• High accuracy and repeatability
• 3D scanning speed
• Portability to work directly on vehicles
• Integration with reverse-engineering software
• Reliable technical support
• An acceptable learning curve for the team

Creaform’s metrology-grade HandySCAN 3D, along with its Scan-to-CAD and Inspection software modules, immediately stood out for its ability to precisely capture parts of any size, shape, material, and surface type. The 3D scanner’s accuracy of 0.025 mm and robust design generated reliable and repeatable results, even in the demanding environment of the company’s shop floor. 

As part of Creaform’s Metrology Suite, the Scan-to-CAD module played a key role in refining mesh data and preparing high-resolution 3D scans for accurate downstream reverse engineering. It enabled the team to clean, align, and convert scan data into accurate parametric solid models—all ready to export into Karbonius’ CAD software.

“The interface was very intuitive, and that helped a lot,” says Forjan. “We were able to export CAD files fully compatible with our design workflow, which made our work so much easier.”

Integrated 3D scanning software modules help designers and engineers refine, reverse engineer, and inspect vehicle components.

Scan-to-CAD helps to refine mesh data and streamlines 3D scans for 3D printing. It also empowers engineers and designers to effectively process and integrate scanned data directly into their reverse engineering and product development processes. The Inspection module is a user-friendly tool for conducting part inspections and generating reports to meet engineering requirements.

‘The impact on the team’s performance was remarkable. Design times were slashed by over 40%, errors from manual 3D measurements were virtually eliminated, and efficiency among the technical team improved.’
—Jacobo Forjan

The team was up and running in no time. With the active support from Creaform’s technical team, Karbonius had the 3D scanner and software modules fully operational within a week. The user-friendly interface and comprehensive training allowed the Karbonius team to feel fully comfortable and productive with the scanner within days.

Tangible boosts to accuracy, productivity, and ROI

The introduction of Creaform’s technologies immediately transformed Karbonius’ product development, particularly through a key project involving the reproduction of the classic car’s side fin. By 3D-scanning the original part, Karbonius quickly generated an accurate, high-resolution CAD model from which precise molds and final carbon-fiber components were produced. This ensured an impeccable fit, significantly reducing the risk of costly revisions.

The precision of the 3D scans substantially reduced the number of iterations required for molds, accelerating validation and production stages. Financially, the system demonstrated an exceptional return on investment (ROI), fully paying for itself within the first year of implementation through time savings and reduced material waste.

‘Creaform’s 3D scanning has fundamentally transformed how we operate. It’s no longer just a tool; it’s an integral part of our production process.’
—Jacobo Forjan

In the future, Karbonius plans to leverage Creaform’s technology across a range of ambitious projects. These initiatives include scanning entire vehicles for custom aerodynamic packages, digitizing rare components for restoration purposes, and automating quality control processes.

“With Creaform, we’re confident to take on bigger, more complex projects,” says Forjan. “This technology has opened new opportunities we once thought were beyond our reach. Thanks to Creaform’s 3D scanning solutions, we can now deliver carbon-fiber parts that set a new standard for quality and performance.”

Published Aug. 5, 2025, by Creaform.