How SCANTECH's NimbleTrack Helps Design Custom Wide Body Kits for the Tesla Cybertruck

The automotive aftermarket industry has seen a surge in demand for personalization, with car enthusiasts around the world seeking ways to make their vehicles stand out. Among the most popular trends is the rise of custom widebody kits—bold, performance-driven modifications that transform both the look and feel of a vehicle. As the industry evolves, companies like Waido are embracing new technologies and bold design concepts to meet the growing appetite for individuality and innovation.

Founded in 2016, Waido Kits has made a name for itself in the automotive aftermarket industry by designing and manufacturing custom widebody kits for car enthusiasts around the world. Known for their commitment to quality, durability, and unique aesthetics, Waido continues to push the boundaries by integrating the latest ABS and CF manufacturing technologies into their creations.

Over the years, Waido has expanded its offerings by collaborating with high-profile clients and globally successful companies and constantly developing new designs. When the Tesla Cybertruck made its much-anticipated debut, Waido saw an opportunity to do something extraordinary: create the custom widebody kit for this futuristic vehicle.

Project Goal

Developed a fully customized widebody kit for the Tesla Cybertruck that enhanced both performance and visual impact. The design needed to be precisely tailored to the vehicle's unique shape and materials—all without access to official CAD files. High-accuracy 3D scan data was essential to ensure a flawless fit and finish, despite the challenges posed by the Cybertruck's unconventional geometry and surfaces.

Understanding the Object: Tesla Cybertruck

The Tesla Cybertruck was not your average vehicle. Measuring 5.9 meters long, 2 meters wide, and 1.9 meters high, and weighing in at 3 tons, it's a behemoth that presents several scanning challenges. Its exterior features mirrored sheet metal panels combined with black plastic parts—two materials difficult to scan due to their reflective and absorptive properties.

In addition, the design process required detailed scans of key components like the charge port, trunk, and sensors—all under various configurations (e.g., open or closed). The technical requirements were strict: high scanning accuracy, comprehensive surface coverage, and a very tight scanning window of just 3 hours.

Challenges of Measuring a Cybertruck

Traditional 3D scanners often struggle with such surfaces, requiring surface preparation sprays or time-consuming marker placement. Using a handheld 3D scanner to measure large components and intricate 3D surfaces was time-consuming and difficult. For a job where time was limited and surface integrity was a priority, those approaches were not viable.

NimbleTrack in Action

Waido opted for SCANTECH's optical 3D scanning system NimbleTrack, which brought together all the essential features needed for this task. The NimbleTrack wireless 3D scanning system is built for precision, speed, and flexibility. Compact yet powerful, it's engineered to transform the way small- to medium-sized parts are measured—offering exceptional freedom and performance in any environment.

Workflow of 3D Scanning

The scanning took place in an underground parking garage, which introduced additional space and lighting constraints. Once a suitable spot was secured, the team set up their mobile scanning station: a laptop cart equipped with a large monitor, a router, portable battery chargers, and—most importantly—the NimbleTrack.

The workflow was carefully structured. First, the entire Cybertruck was scanned in its default state. Next, the team captured data from specific configurations: the trunk and charge port in both open and closed positions, and a high-resolution pass over all external sensors and their surrounding surfaces. The entire scanning process, including setup and multiple passes, was completed in just over two hours—well within the 3-hour window.

NimbleTrack precisely captured wheel arches, side skirts, bumper mounting points, and door-fender junctions to ensure seamless integration. Critical measurements also include symmetry reference points to avoid visual imbalance and aerodynamic zones like rear spoiler bases to optimize airflow. High-precision scans of these areas enabled custom kits to match factory bodylines, prevented interference during movement, and maintained structural integrity, while adapting for materials.

The Advantage of 3D Scanning with NimbleTrack  

• Completely Wireless Operation: Without cumbersome cables, the technician had the freedom to move around the vehicle with ease. The wireless nature of the 3D scanner made the process smoother, faster, and more flexible.

• Compact, Plug-and-Play: Its lightweight design allowed users to measure the vehicle effortlessly and efficiently. The i-Tracker measuredjust 57 cm in length and weighed only 2.2 kg, allowing users to move freely. Paired with the lightweight 3D scanner, which weighed just 1.3 kg, the system enabled extended scanning sessions without causing fatigue—perfect for detailed measurements across the vehicle.

• Markerless Scanning:With no need to place physical markers on the vehicle, the team saved significant setup time and avoided potential surface damage or contamination. This was particularly important given the polished finish of the Cybertruck's body panels.

• Blue Laser Technology:The blue laser 3D scanner effectively captured detailed and accurate data from both reflective and dark surfaces—precisely what was needed for the Cybertruck's challenging exterior.

• Precise data:NimbleTrack delivered highly accurate 3D measurement results with an accuracy of up to 0.025 mm and maximum volumetric accuracy of 0.064 mm across the whole range. This allowed users to capture intricate surface details and complex geometries of vehicles with exceptional precision.

Compared to Common Market Solutions

Most competing 3D scanning solutions fall short in one way or another. Some can deliver the required accuracy but are tethered and lack the flexibility of wireless systems. Others are wireless but cannot handle reflective or dark surfaces effectively. Many still rely on markers, which slows down the scanning process and introduces logistical overhead. And even the few systems that do tick all the technical boxes tend to be prohibitively expensive, making them a poor fit for high-volume or agile design workflows. SCANTECH's NimbleTrack stood out as the only solution that combined all the necessary capabilities—without compromise.

Outcome

The resulting scan data was incredibly precise, enabling Waido's designers to model and manufacture a body kit that fit the Cybertruck like a glove. Based on this data, Waido went on to produce a widebody kit dubbed the Cyberbeast. The Cyberbeast has become the top-selling item in Waido's product portfolio, receiving attention from across the custom automotive community.

Conclusion

Waido's successful project with the Tesla Cybertruck demonstrates how cutting-edge scanning technology like SCANTECH's NimbleTrack can unlock new creative possibilities and streamline product development—even when faced with challenging surfaces, tight timelines, and demanding technical requirements.

This collaboration sets a new benchmark for custom automotive design—one where precision meets innovation, and where bold ideas become road-ready reality.