From Handmade to CAD: Reverse Engineering a Custom Wooden Boat

A Reverse Engineering Success Story in Marine Manufacturing

A handcrafted wooden boat arrived at our shop with a clear goal to launch Morgan Boatworks, the start-up plans to market an 11-foot sport boat capable of building its own fan base. The cedar strip fishing wherry can be peddled, paddled, rowed or sailed. It can be transported on a rooftop, and loaded and unloaded single-handed. But before any of that could happen the client needed a clean, accurate CAD model that could be used for modern sheet-based manufacturing, taking this one-of-a-kind vessel and bringing it to the greater market. No digital design or manufacturing files existed of the boat because the entire structure had been built skillfully by hand.

This wasn’t a typical hull scan. The boat was shaped from curved cedar strips, assembled without molds or templates. Precision and communication mattered at every step to ensure the shape and intention of the boat would be maintained throughout the process.

The Challenge: Converting Craftsmanship into CAD

This boat wasn’t built from a kit or based on digital plans. It was a true one-off, the hull was formed on pre-conceived molds, but those templates were prototypes crafted as the boat was taking shape for the first time. As it took shape over the untested forms, the bent strips were allowed to stray and gave the boat a more consistent natural shape than the imperfect forms would have allowed. The newly minted hull was an improvement on the original form layout, but those forms were now obsolete. A 3D scan of the finished hull was the only way to create new forms from its final shape.

Our task was to:

• 3D scan the full, as-built geometry of the boat

  
  

• Apply corrections in CAD like enforcing symmetry, smoothing the hull loft, and filling in any missing details

  
  

• Deliver precise models that could be used for CNC workflows

Handcrafted Origins

Before scanning even began, we took time to understand how the boat was built. Here’s what made it special:

• It was built upside-down on a strongback, a rigid plywood reference frame also built by hand. Temporary forms, which shape the hull, were fastened to the strongback and carefully spaced and leveled.

• Full-length cedar strips were glued edge to edge using a cove and bead joint, creating tight curves without gaps. The original boat had no prefabricated elements.

• The bow stem and stern were laminated in place and became permanent structural parts of the boat.

• After the hull was glassed inside and out, internal ribs were added. These had to be templated and shaped individually, based on the largest cross-section at each location.

• Deck framing, rails, and hardware were fit manually, adjusted in place to ensure everything sat flush and true.

Every step involved shaping, checking, and adjusting to preserve Morgan Boatworks' vision. Our job was to preserve that level of care while turning it into clean, accurate CAD files ready for CNC, drawings, and repeat builds.

Planning the Approach

Our team reviewed photos and technical needs, then broke the job into distinct phases. Estimation involved collaboration across multiple departments to assess the expected effort for both scanning and modeling. We worked closely with Morgan Boatworks to clarify which features were critical, how the model would be used, and what construction details would require special attention.

Key preparation steps included:

• Understanding the hand manufacturing process that contributed to the unique design, and how Morgan Boatworks wanted to move forward with manufacturing

  
  

• Verifying required model detail and tolerances

  
  

• Creating a modeling strategy that would support a smooth, manufacturable design

3D Scanning Execution

When the boat was delivered to our Calgary shop, our team met with Morgan Boatworks to discuss structural details and modeling priorities. The boat was placed on stands, minimizing contact and allowing full access for scanning coverage.

We used:

• Creaform MetraSCAN Black Elite for high-precision scanning of the hull and internal features

  
  

• Creaform HandySCAN Black Elite for tighter areas near the bow

  
  

• Creaform.OS to align, merge, and clean scan data

Because the boat's positioning was stable and well-supported, we avoided any need to reposition or flip it. The scan merge process was smooth and efficient, and no significant artifacts were introduced from contact points.

CAD Modeling and Verification

Our modeling team developed a strategy to create a continuous, smooth loft representing the true surface of the boat. Instead of splitting the model into sections, we focused on a unified shape that captured the overall form and curvature. Using tools like Geomagic Design X allowed us to work directly with the scan data to extract these complex profiles and features. Powerful surfacing tools, advanced solid modelling capabilities, and a feature-based model allowed us to work effectively to produce a model.

Outcome and Delivery

The final CAD model was delivered in a format suitable for downstream use in standard design software. A follow-up session was held to walk through the model and answer any questions. Morgan Boatworks looks forward to bringing the boat into production as its introductory product. From the CAD model, the boat will be available to fit the buyer’s needs and abilities - from plans only, to templates, CNC-cut precision kits or the fully built ready-to-play boat.

What This Project Shows

Reverse engineering isn’t just about scanning a shape. It’s about understanding how something was built, capturing what matters, and creating something others can build from.

This project is a great example of how a one-of-a-kind design can be preserved, corrected, and made repeatable without compromising the craftsmanship behind it.

Connect with Morgan Boatworks

Interested in Morgan Boatworks’ 11-foot sport boat or future builds? You can reach them directly at wadeswoodenboats@gmail.com

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Have a Similar Project?

Whether you’re working with hand-built prototypes, legacy parts, or complex surfaces, Rapid3D can help you capture, correct, and convert your physical designs into production-ready CAD.

Get in touch with our team today to discuss your 3D scanning or reverse engineering requirements.