Reinforcing Cracked Caravan Corners with 3D Scanning & Printing

Solving the cracked corner issue

When a local customer discovered structural cracks in the rear corners of their caravan, they needed a durable and cost-effective solution. Traditional repair methods like fiberglass patches or bogging lacked flexibility, risking further damage over time. Using 3D scanning and additive manufacturing, we engineered a custom cap solution to strengthen the caravan’s structure while allowing for necessary movement.

How damaged was the Caravan Body?

The customer recently purchased a caravan for camping trips but overlooked hidden structural issues, including significant cracks where the roof meets the rear window face. These large-radius corners are a common weak point in caravan bodies. A local repair shop recommended sanding everything back and fabricating a cap to reinforce the area. Typically, such repairs involve fiberglass, but cracks generally re appear in these caravan designs as there is no give for the body to flex, therefore requiring a more flexible, adaptable approach.

Fiberglass body crack repair

• 3D Scanning the Damaged Area: We used our Creaform HandyScan 700 to precisely scan the cracked sections of the caravan’s rear corners.

• The scan data was processed in Creaform VXmodel software to extract a clean surface profile for designing the replacement caps.

Generating the CAD Model

• The surface data was imported into an Autodesk Inventor IPT file.
• A 3D model was created with additional margin beyond the cracks for better reinforcement.

Material Selection & Printing Orientation

• We chose white PETG for its durability and flexibility, ensuring structural integrity without making the repair too rigid.
• The part was 3D printed with full infill to maximize strength & was printed vertically to produce the best finish.

Final Production & Installation

• The CAD Generate support structure on the printed cap was sanded completely off.
• The caravan body was primed and prepped before applying adhesive to bond the caps securely.
• Additional sealant was applied around the edges of the cap to body to ensure a watertight seal.

• Once the full caravan body repairs were completed, the entire section was repainted for a flawless finish.

Results: A Strong, Flexible Repair

This 3D-printed solution offers significant advantages over conventional fiberglass or bogging methods:

• Structural Support Without Rigidity – The cap strengthens the area while allowing slight movement, preventing future stress fractures.
• Custom Fit & High Precision – The 3D scanning process ensured an exact match to the caravan’s contours.
• Cost-Effective & Long-Lasting – A affordable option compared to fiberglass work, while offering a durable fix.

While all repairs have a lifespan, this solution effectively prolongs further cracking and allows the caravan owner to continue enjoying trips without worrying about immediate structural failures.

Do you have a unique repair challenge, we can engineer a tailored solution using advanced 3D scanning, CAD, and printing technologies. Contact us today to discuss how we can help restore and reinforce your caravan or motorhome.