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Mid-America Car Inc., a railcar repair and locomotive maintenance company based in Kansas City, Missouri, has been serving the North American rail industry for decades. Known for its comprehensive services—from modification and repairs to sophisticated painting—this family-owned business is strategically located to serve rail systems such as CPKC, Burlington Northern Santa Fe (BNSF), Norfolk Southern (NS), and Union Pacific (UPRR). The company also provides mobile services, catering to clients across the United States, Canada, and beyond. Recently.
Mid-America Car took on a highly technical project: developing a means to safely and efficiently attach a massive snowplow to the front of a non-operational locomotive.
The challenge: Tackling product development and high-stakes safety issues
Fixing an oversized snowplow to a locomotive may sound straightforward, but the reality was anything but simple. It required a series of changes to both the locomotive and the snowplow, including removing existing components, reshaping metal surfaces, and ensuring the final attachment was secure and robust to withstand heavy plowing.
“Internally, we have a strong focus on ensuring every detail is accounted for,” explained Patrick J. Patrick, Senior Managing Director of Locomotive Quality. “But with the potential to complete five or more similar projects, we recognized the importance of incorporating new technologies to help us from the outset.”
The team faced several roadblocks. First, the company lacked a staff engineer, making it difficult to produce detailed technical drawings. Second, without repeatable 3D measurements, there was no effective way to accurately model the components for a properly engineered assembly. Finally, the stakes were high: any miscalculation could result in costly rework, process failures, or even injuries to personnel.
“Given the complexity of the task and the potential occupational health liabilities, we needed a something that would help us avoid these pitfalls,” added Patrick. “We were determined to eliminate any room for error by investing in metrology equipment.”
The solution: Unlocking new production capabilities with 3D scanning
The decision to adopt 3D scanners was driven by opportunity. Mid-America Car had previously hosted a demonstration of Creaform’s 3D measurement tech, and the team was impressed by the ease of use without sacrificing accuracy and performance. “The demo showed us what was possible,” explained Patrick. “It became clear advanced 3D scanning technologies was the only viable path forward.”
The company’s main requirements were clear: they needed a product that was cost-effective, easy to implement, and capable of producing CAD drawings quickly and accurately. Creaform’s HandySCAN 3D|MAX Series metrology 3D scanner for large parts and Creaform Metrology Suite, checked all these boxes.
With Creaform’s 3D scanners and software in place, Mid-America Car began integrating the products into its operational workflows. The onboarding was smooth, and team members quickly became comfortable using the equipment. “Not everyone learns at the same pace,” Patrick mentioned. “But even with that in mind, the adoption of the devices and software was remarkably fast and efficient.”
The Mid-America Car team used Creaform’s solutions to 3D scan the locomotive and the oversized snowplow and create accurate digital models that were then converted into detailed CAD drawings. These 3D models enabled staff to visualize the alterations as needed, down to the millimeter, ensuring a perfect fit for the snowplow attachment.
3D scanning large locomotive parts is made easier for Mid-America Car thanks to the HandySCAN 3D|MAX Series metrology 3D scanner “Creaform’s 3D scanners are incredibly user-friendly,” Patrick noted. “The graphical user interface is intuitive, and the suite of tools available makes it easy to produce high-quality 3D models in a fraction of the time compared to traditional methods.”
The results: Concrete gains in time and cost-effectiveness
Implementing HandySCAN 3D|MAX Series and Creaform Metrology Suite has already yielded significant benefits for Mid-America Car. The team now has the ability to complete elaborate projects more quickly and with greater accuracy, reducing the risk of costly human error. “The convenience and reliability of Creaform’s solutions have made a tangible impact on our operations,” Patrick said.
Beyond the immediate snowplow project, the company expects long-term benefits, including a quick return on investment, expanded production capacity, and a boost in its reputation for confronting multi-faceted design problems. Worker protection is no longer a concern, as the accurate digital models reduce the need for trial-and-error adjustments, minimizing the exposure to injuries.
“Creaform has given us the tools to take on projects that were previously out of reach,” Patrick added. “We’re now positioned to expand our customer base and deliver solutions that meet the highest quality and regulatory standards.”
With the success of this project, Mid-America Car plans to use 3D scanning technology for multiple snowplow retrofits and other tweaks. The company sees this as just the beginning of its journey with metrology. “As our familiarity with the metrology grows, so does our potential,” Patrick said. “We’re excited to see how far we can take this.”
Creaform Metrology Suite is a complete platform to post-process 3D scans and ready them for CAD remodelling. “The Creaform/Ametek team went above and beyond to make our transition to 3D scanning as painless as possible. Their support has been invaluable, and we look forward to continuing this partnership,” Patrick indicated.
Mid-America Car’s adoption of Creaform’s 3D measurement solutions marks a huge step forward in its approach to designing locomotive assemblies. By embracing cutting-edge 3D scanners, Mid-America Car is ready to lead the way in railcar and locomotive engineering.
Published 03/11/2025