Honda Motor Company
I was fortunate enough to work on the Honda account at the Tunbridge Wells based agency nexus|H as part of a team charged with re-creating the Honda Accord in its entirety in 3D for European brochures, publicity shots and videos.
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All cars are of course designed using sophisticated 3D computer programs but that data never, ever leaves the factory for fear of industrial espionage by less scrupulous manufacturers.

In any case, that data is in the form of complex NURBS sets used for manufacturing. For photographic and video use, efficient subdivision surfaces are the order of the day.

It should also be noted that when these models were created only two actual cars existed, yet photographs of hundreds of trim, option and colour combinations were required before launch.
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Sometimes the base data would be accurate but messy meshes, sliced, diced and triangulated from the original CAD files. Too many polygons and trashed normals means that this would not render correctly. After being 're-topologised' into subdivision surfaces using Luxology's modo, the part would render accurately at any resolution.
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Some of the most complex engineered parts in modern vehicles are the lamp clusters. Representing a vital part of the design 'jewellery' these clusters are multiple layers of reflectors and filters.
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Where CAD data was not available but the physical part was, the object would be taken to a specialist automotive laser scanning company. The returned data is very accurate but too dense. Re-topologising the mesh into subdivision surfaces reduced the data overhead by 40 times. Modelling wheels is very satisfying for some reason.

Below are a selection of other parts I modelled for the project.
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All the modelling was carried out in Luxology's modo. The images here are test renders from modo 301. For the project, final assembly was performed in Maya with final rendering carried out in Bunkspeed's Hypershot


I have created a short tutorial on re-topologising CAD data in modo. You can find it
here