By Paul Salmon FCILT, FSCM
Introduction
The phrase “digital transformation” often brings to mind artificial intelligence, predictive analytics, or cloud-based orchestration platforms. Yet some of the most profound advances in logistics and defence support come from technologies that bridge the physical and digital worlds. Among these, 3D scanning stands out as a quiet enabler of efficiency, accuracy, and resilience across the supply chain.
A 3D scanner captures the physical characteristics of an object and converts them into a precise digital model. What began as a niche tool for design studios and reverse engineering has matured into an industrial and defence-grade capability with direct implications for availability, agility, and sustainment. This article explores the mechanics of 3D scanning, its applications across logistics and defence, the benefits and barriers to adoption, and its likely trajectory over the next decade.
How 3D Scanning Works
3D scanners operate by capturing the geometry of an object and generating a “point cloud” or mesh that represents its shape in three dimensions. Several underlying technologies are commonly employed:
Laser Triangulation: Projects a laser onto the object; sensors calculate geometry from the angle of reflection. Structured Light: Uses projected patterns (e.g., grids or stripes) and records their distortion on the surface. Time of Flight (ToF): Measures how long it takes a pulse of light to bounce back, similar to LIDAR. Photogrammetry: Stitches together multiple 2D images into a 3D model using algorithms. Contact Probing: Physically touches points on the surface — slower, but highly accurate for precision engineering.
The choice of scanning method depends on the context: defence maintenance depots might use metrology-grade scanners for aircraft components, while warehouses may favour structured light systems to measure pallets in seconds.
Types of 3D Scanners
Handheld Scanners – Portable and flexible, widely used for maintenance, field repairs, or capturing volumetrics in warehouses. Stationary / Fixed-Mount Scanners – High precision, used for quality control and manufacturing inspection. Industrial Metrology-Grade Scanners – Ultra-precise systems capable of tolerances under 10 microns, essential for aerospace and automotive supply chains. Mobile / Drone-Mounted Scanners – Enable terrain mapping, site surveys, or scanning large depots and ports.
This diversity makes 3D scanning adaptable across both commercial and military logistics settings.
Applications Across the Supply Chain
1. Reverse Engineering and Obsolescence Management
One of the most significant applications is in reverse engineering. In defence environments, equipment often outlives its original manufacturers or documentation. A 3D scan allows engineers to recreate legacy or obsolete components with precision, supporting sustainment without relying on fragile or unavailable supply lines.
2. Quality Control and Assurance
In manufacturing, scanners are routinely used to compare finished products against CAD models. This ensures compliance with tolerances, reduces defects, and enhances consistency across production runs.
3. Packaging and Volumetric Analysis
In warehousing, volumetric 3D scanners are increasingly integrated into automated packing lines. By capturing the exact dimensions of items, packaging can be optimised to minimise waste, reduce shipping costs, and support carbon reduction goals.
4. Maintenance, Repair, and Overhaul (MRO)
In MRO environments, 3D scanners allow rapid assessment of wear or damage. Instead of dismantling entire assemblies, technicians can scan parts in situ, determine deformation, and decide whether repair or replacement is feasible.
5. Digital Twins and Predictive Analytics
3D scans underpin the creation of digital twins — virtual models of assets that mirror real-world condition. This enables predictive maintenance, improved lifecycle cost modelling, and integration into decision support systems.
6. Battlefield and Deployed Logistics
Portable 3D scanners are emerging as a tool for forward operating bases. Damaged parts can be scanned on-site, digitally transmitted to additive manufacturing hubs, and rapidly reproduced. This shortens lead times and reduces reliance on vulnerable resupply routes.
Benefits for Supply Chain and Defence
The adoption of 3D scanning offers a series of tangible benefits:
Accuracy and Repeatability – High precision reduces errors in measurement, packing, and reproduction. Time Savings – Faster than manual measurement or traditional inspection methods. Sustainment and Availability – Supports rapid part replacement, reducing downtime. Reduced Waste – Optimises packaging and prototyping, cutting material use. Improved Decision-Making – Enhances forecasting and maintenance planning via digital twin integration. Interoperability – Scanned models can be shared across digital platforms, supporting multinational operations.
For defence specifically, 3D scanning contributes to the broader goals of agile support, resilience, and mission assurance in contested logistics environments.
Barriers and Limitations
Despite its promise, several challenges remain:
Cost of Equipment – Industrial-grade scanners are expensive, particularly for large-scale adoption. Training and Expertise – Skilled operators are needed to process scan data and integrate it into workflows. Data Management – Point-cloud files are large and complex, creating storage and integration burdens. Surface Limitations – Highly reflective, dark, or transparent surfaces may require additional preparation. Environmental Constraints – Dust, humidity, and extreme temperatures can impair accuracy in field deployments.
Defence supply chains, with their varied conditions and operational pressures, must carefully balance these limitations with the potential benefits.
Case Examples
Aerospace: Aircraft components are scanned to ensure precision in manufacture and maintenance. Boeing and Airbus have adopted scanning for quality assurance. Automotive: OEMs use scanners for rapid prototyping and to shorten design cycles. Defence: NATO nations are experimenting with forward-deployed scanning units linked to additive manufacturing hubs. UK defence has trialled 3D scanning in naval maintenance, scanning valves and fittings for ships to reduce downtime. Warehousing: Major logistics providers employ 3D volumetric scanners to automate cartonisation, cutting packaging waste and improving cube utilisation.
The Future of 3D Scanning in Supply Chains
Looking ahead, several trends point to deeper integration of 3D scanning into logistics and defence:
AI-Powered Analytics – Scans will increasingly be analysed automatically for defects, reducing reliance on human inspectors. Augmented Reality Integration – Maintenance staff may overlay scan data with digital instructions for repair guidance. Edge Processing – Devices will process scans locally, transmitting only usable data rather than massive point clouds. Standardisation of Data Models – Defence and industry will need shared standards for scan data to ensure interoperability. Integration into Control Towers – 3D scan data could feed directly into supply chain control towers, enhancing visibility of asset condition and readiness.
In defence, this evolution ties directly into the concept of contested logistics — the need to sustain forces under pressure from disrupted supply chains. Portable scanners, integrated with additive manufacturing and secure digital networks, represent a key enabler of resilience.
Conclusion
3D scanning is more than a design tool. It is fast becoming a core logistics capability, providing the bridge between the physical object and the digital model that drives modern supply chain decision-making.
For industry, this means better packaging, higher accuracy, and reduced waste. For defence, it means the ability to keep platforms in service, sustain operations in austere environments, and reduce reliance on fragile global supply chains.
The challenge lies not only in the technology itself, but in integrating it into the wider supply chain ecosystem — ensuring data flows seamlessly, operators are trained, and benefits are realised at scale.
As supply chains continue to digitalise, 3D scanning will play a crucial role in shaping a future where availability, resilience, and sustainability are not just aspirations, but operational realities.
