Using our technical expertise to reverse engineer a complex transmission
Mastering minute component replications
Our client, a global industrial brand, wanted a visually striking and highly accurate 3D asset of a complex ‘Traxon 12 TX 2210 TD’ transmission found in modern trucks across Europe, right down to the most minute components. It wasn’t just a case of modelling what you could see – but also all the parts you couldn’t, deep inside. By combining our specialised photogrammetry capabilities and mechanical engineering understanding we created a working transmission from scratch, with each individual component true-to-life in terms of placement, scale, and functionality. Our team utilised their exceptional strategic and practical knowledge and market-leading creative skills, turning our client’s visions into reality and proving the value of highly accurate digital assets. The client will use this master asset in their internal and external communications, adding to their growing digital asset library and improving sales and marketing material. This innovative digital asset is the critical heart of a series of multi-platform applications – from ongoing marketing and display purposes to operational use in the field. Photogrammetry uses detailed photographs to capture 3D data allowing the extraction of minute detailing and surface materials of an object. Due to the number of components and complexity of the transmission, we selected this method to create a reference for the remodelling stages, ultimately speeding up the process and enhancing the precision of the final asset. With very few official documents or materials available to help us map out the workings and construction of the gearbox, we had to rely heavily on the knowledge and understanding we’ve amassed over two decades of working in this field. This was supplemented with the resources we carefully gathered during the documentation and disassembly stages. Read on to learn how we replicated this complex transmission in the 3D world.
Lead Studio
Technology
Services
Photogrammetry | 3D Modelling
Dismantlement
Dismantlement
Before we could build the digital asset we first had to dismantle the physical! To kick start the project, we first visited a breaker’s yard full of decommissioned vehicles to document a ‘Traxon 12 TX 2210 TD’ transmission (gearbox) for modern trucks, which was then broken down into all its individual parts by our experienced modelling team. To ensure we had enough in-depth documentation to be able to eventually put the asset back together digitally via the reverse-engineering process, we captured hundreds of reference photographs and videos which helped document and organise the components right down to the last nut and bolt. This enabled us to understand every inch of the transmission, from the inside out, to perfectly replicate the asset and master the internal components and external chassis.
Reverse Engineering
Reverse Engineering
The intensive process of photogrammetry (recording, measuring, and interpreting photographic images) began shortly after the dismantlement and documentation phase was complete. Hundreds of images were taken of each individual part, in some cases using specific lighting and positioning to capture every detail. The team made the most of our in-house photographic skills and industry-leading equipment to convert the images captured into 3D geometric objects, which would be used during the 3D Modelling phase as a building block to precisely piece the master asset together digitally.
3D Modelling
3D Modelling
We started the remodelling process by recreating the geometry of every single part of the transmission. This technique highlights the serious attention to detail within our work, ensuring that the assets don’t just have visual impact but are operationally accurate and have the potential to be used in different applications, such as apps or VR experiences. This involved replicating the smaller details like the number of individual teeth on each gear. Since this was a large gearbox, as you can imagine there were a lot of teeth to count... 600 to be exact, each located on the main shaft and layshafts. Overall when you add the planetary gearset too, it was close to 1000 teeth! The photogrammetry was used as a template for scale and proportion which enhanced the accuracy of the model and reduced the total turnaround time for the entire project. In circumstances where two pieces connected, the team referred back to real parts from the transmission to ensure the precision of measurements.
Digital Reassembly
Digital Reassembly
Combining our practical and technical skills, we began digitally reassembling the entire transmission piece by piece. Using the references gathered from the breaker’s yard was essential, along with accurate calculation, intuition, patience, and a bit of strategic trial and error to complete the task. During the reassembly, we recreated a set of life-like digital bolts and placed them back into their respective locations – it was just like assembling the real thing! Once assembled and functioning correctly, our 3D digital artists added relevant textures and paint to the materials, from the internal components to the outer chassis for a realistic finish. Even the smallest components that are out of sight but were by no means out of mind, are all accurately replicated. Our team went above and beyond to create this impressive digital asset which the client is thrilled with.
