How Bode – Die Tür Improved the Manufacturing of Door Systems for Rail Vehicles Using 3D Scanning Technology

Meet Bode - Die Tür, experts in door systems for rail vehicles. Founded in 1968, BODE is a reliable partner of the world’s leading vehicle manufacturers and develops customized door systems for rail and road vehicles. The company specializes in the production of flexible, modular door and entry solutions made from proven components that are perfectly suited for any type of train. BODE’s door systems are more robust, reliable, and intelligent than ever before. They ensure that passengers can board and exit smoothly and safely, no matter where they are traveling.

The Challenge: 3D Measurement Issues and Time‑Consuming Product Analyses

Before implementing 3D measurement technology, inspection and evaluation using conventional 3D measurement methods required significantly more time. Inspecting large rail‑vehicle doors in test stands or on-site was also laborious and time‑consuming.

“We need to guarantee the precise manufacturing of parts, verify the dimensional accuracy of our door systems, and ensure that all components meet strict safety standards,” explains Matthias Voit, Head of the Operational Quality Assurance department. “It became clear that conventional 3D data capture was no longer sufficient for rising production volumes.”

Because of additional applications that also required greater efficiency, Bode sought a better, faster, and more precise 3D measurement solution. “We had several criteria,” Voit says. “We needed a solution that offered high accuracy, user‑friendliness, and flexibility to measure various door systems quickly and precisely.”

The Solution: HandySCAN BLACK+ Elite™ with Perfectly Integrated 3D Scanning Software

The Bode - Die Tür team chose the HandySCAN BLACK+ Elite 3D Scanner from FARO CREAFORM, in combination with the Scan-to-CAD and Inspection software modules, both part of the Creaform Metrology Suite™. Easy handling, rapid deployment, and incredible accuracy, this 3D scanning solution integrates seamlessly into Bode’s workflows, especially during first‑article inspections and quality control in incoming goods inspection.

“The training was quick, and the solutions were very intuitive to operate. Most of my colleagues were fully familiar with all solutions within just a few weeks,” says Voit.

“The installation of doors on rail vehicles requires precise adjustment of components to ensure proper operation. However, on one of our prototypes, a door leaf in a test stand deviated from the specified manufacturing tolerances, impairing correct functionality. These tolerance deviations affected both the fit during assembly and the functioning of the door, something that is simply unacceptable,” Voit continues.

To identify these tolerance deviations more precisely, a HandySCAN BLACK+ Elite was used. The door system’s data was captured in real time, and the deviations were visualized using a color comparison with the 3D model. The colormap clearly showed the differences between the actual and nominal condition of the door leaf. Depending on the deviation, a color scale was used to indicate the accuracy and location of the errors.

A technician uses the HandySCAN BLACK+ Elite to scan a door system directly in the test hall.

“Thanks to the precise capture of the tolerance deviations, staff in the testing department were able to react more quickly. The identified deviations enabled targeted adjustments of the components. The visualization of the 3D scans not only revealed the exact deviations but also made it possible to decide immediately how these could be corrected in the production process through small adjustments,” adds Voit.

FARO CREAFORM’s 3D scanning software helps technicians identify deviations on rail‑vehicle doors using a colormap.

The Results: Less Effort, More Accuracy, Significant Savings

Clear visualization of tolerance deviations allowed Bode - Die Tür’s development team to address issues immediately and optimize product design. The improvements were substantial:

• Fewer problems in product development: Fast identification and correction of deviations led to a significant reduction in testing efforts.
• Time and cost savings: Faster inspections and improved presentation of results reduced inspection workload and testing times.
• Improved quality: Thanks to high accuracy, product quality could be increased, and inspection effort reduced.

By introducing FARO CREAFORM’s 3D technologies, Bode - Die Tür further increased efficiency and accuracy in both quality assurance and product development. “The HandySCAN BLACK+ Elite and the 3D scanning software have taken laser measurement to a whole new level compared to our previous system,” Voit concludes.