Automotive reverse engineering
Audi 80 Rear Spoiler Redesign
A scan-driven spoiler redesign that increased the rear spoiler height while preserving its relationship with the original Audi 80 bodywork.
The challenge
Design around reality
The client wanted a taller rear spoiler without losing the original component's mounting alignment, body fit, or visual character. They supplied 3D scans of the existing spoiler and the vehicle's rear body section so the redesign could be developed against real geometry rather than estimated dimensions.
Engineering approach
Reviewed the supplied spoiler and rear-body scan data to identify the original mounting areas and surrounding clearances.
Reconstructed the relevant surfaces and increased the spoiler height while preserving its connection to the original mounting geometry.
Refined the surface transitions so the taller form remained visually balanced with the Audi 80 rear profile.
Checked the redesigned geometry directly against the scanned vehicle body for fit and interference.
Result
A fit-led final design
The completed model provides a taller, more prominent spoiler that remains integrated with the Audi 80 body shape. The scan-based workflow reduced fitment guesswork and preserved the original installation relationship.
Have a similar fitment problem?
Send your scan data and project requirements for a practical review.