Once the vehicles were disassembled, the parts were assigned for modeling. Most of the more than 4,000 unique parts of each vehicle were measured using handheld interrogation tools, such as calipers, micrometers, and protractors. Larger and more complex parts, like the vehicle hull, were measured by government and contractor teammates using laser‑scanned data. The measurement data was then entered into SOLIDWORKS, a 3D modeling computer-aided design and engineering application. OEM-provided models were obtained and used when available for the greatest accuracy of design.
The technical data package includes 3D models of every lowest-replaceable unit on the vehicle, as well as roughly 500 unique assemblies and sub-assemblies. In addition, the package includes essential metadata, such as part numbers and descriptions for each part. A key contributor to the success of this effort was a model user’s guide written by the 3D systems development team and refined throughout the task. The guide established best practices and standardized procedures for developing the models from the ground up. After each part was measured and modeled, it was run through a quality-control process for accuracy. Finally, the physical parts were stored in a Booz Allen warehouse until needed for the reassembly process.