How Wilderness Vans Uses 3D Scanning to Engineer Smarter Van Builds

When Wilderness Vans, a Canadian custom van builder known for their clean, functional builds, began working with Rapid3D’s van scan data, their goal wasn’t just to visualize space, it was to engineer better interiors from the ground up.

With Rapid3D’s scan of the 2025 Ram ProMaster 3500 159"WB Extended Super High Roof, captured with FARO Creaform’s professional-grade 3D scanning technology, the Wilderness Vans team built a workflow that transforms raw scan data into a precise, repeatable foundation for their interiors, without sacrificing the flexibility needed for custom builds.

Working from the Mesh as the Foundation

Rather than starting from an abstract or idealized vehicle model or having to take hand measurements, Wilderness Vans begins their process with the raw scan mesh, using it within their design and modeling environment as the geometric reference for the entire build. This gives their team access to the true, as-built geometry of each van, capturing every curve, rib, and real-world variation that would otherwise require extensive manual measurement or templating.

Their first key step is using this mesh to design their proprietary rib system. These ribs form the structural backbone for the rest of the interior, defining the wall and ceiling geometry in a way that is precisely matched to the actual van body.

This is where scanning shows its real value: the ribs are not theoretical or nominal. They’re derived from real geometry, creating a reliable foundation that all subsequent CAD design builds upon.

From Ribs to Profiles: Creating a Clean Design Framework

Once the rib system is established, Wilderness Vans derive clean wall and ceiling profiles from it. These profiles act as simplified, CAD-friendly reference geometry that makes designing cabinetry, fixtures, and layouts far more efficient.

At this stage, the workflow strikes a smart balance:

The simplified profiles drive most of the design work, while the original scan mesh remains in the background as a reference layer. This allows the team to continuously check clearances and interactions with hidden or complex areas such as:

• Roof components

• Window cutouts

• Electrical routing

• Plumbing and insulation zones

In other words, the mesh never disappears. It quietly ensures everything fits, even when it’s out of sight.

Designing with Confidence, Not Guesswork

With both profiles and mesh in play, Wilderness Vans is able to design full interior systems with confidence. Cabinetry, beds, galley units, and storage solutions are modeled knowing they will fit in the real van, not just on screen.

This approach dramatically reduces rework, test fitting, and last-minute adjustments on the shop floor. Instead of discovering issues during installation, potential conflicts are resolved in CAD.

The result is a final model that is not only visually polished but grounded in real geometry.

From Digital to Physical

The final step is where it all comes together: implementation in the real van.

The finished interior closely matches the CAD model, validating the scan-based workflow from start to finish. The rib system, cabinetry, and structural elements all align with the vehicle body as intended, showcasing how scan data can be used not just for visualization, but for true engineering and fabrication.

Why This Matters

Wilderness Vans’ process highlights a powerful use of 3D scanning in van conversions:

• Not just designing inside a van

• But designing from the van itself

By starting with reality and building upward, they’ve created a workflow that is more accurate, more repeatable, and more scalable than traditional build methods.

It’s a great example of how scan data can serve as a digital foundation for modern, high-quality van interiors.

If you’re a van builder looking to improve fit, reduce rework, and streamline your design process, this is what scan-based design looks like in practice.