Geomagic Design X 2025.1: Faster, Cleaner Scan-to-CAD

Reverse engineering is often a race against the clock. You’ve got legacy parts to capture, tooling that needs replacing, or customer components that have no CAD – and you need accurate parametric models quickly, without wrestling messy scan data.

The new Geomagic Design X 2025.1 release is built for exactly that. It adds powerful new tools for cleaning scan data, improves feature and surface modelling and tightens integration with your scanners and CAD systems.

As a Geomagic Platinum Partner, OR3D is here to help you get the most from this release – from planning your upgrade to designing workflows and training your team.

Clean Scan Data Faster with Shrink Wrap & Improved Mesh Tools

Bad scan data slows everything down. Design X 2025.1 focuses heavily on making that first stage faster and more reliable.

New Shrink Wrap tool

The headline addition is the Shrink Wrap tool. It lets you:

• Create a single watertight mesh from one or more meshes
• Capture only the external faces of a part
• Repair mesh topology along the way

In practice, this means you can go from messy, multi-body scan data to a clean, watertight mesh in far fewer steps – ideal for:

• Reverse engineering
• Package design and clearance studies
• Shelling and light weighting
• 3D printing and downstream simulation
• Automated and Semi Automated surface modelling workflows

Faster, smarter decimation and mesh processing

Design X 2025.1 also improves performance and control in mesh processing:

• Decimate command now delivers 2 – 4× faster performance while retaining design intent and producing more robust, adaptive results.
• More informative warning messages and a more useful Average Mesh preview help you spot issues early.
• Global Remesh and the Normal Information Wizard benefit from improved processing performance for smoother, more predictable results.

For you, that translates to less time waiting on processing bars, and more time modelling.

Build Better Reverse-Engineered Models Inside Design X

Once the scan is under control, the focus shifts to rebuilding a high-quality parametric model. Design X 2025.1 introduces several feature modelling upgrades that cut out repetitive work and give you more control.

Enhanced feature patterning and Booleans

New and improved tools include:

• Pattern Faces in Linear, Circular, Curve, and Mirror patterns – perfect for quickly recreating repeated features around a part.
• The ability to retain Tool and Target Bodies in Boolean features, so you can experiment without losing reference geometry.
• More control when creating features by choosing target bodies for Merge and Cut Result operations during solid modelling and surface modelling tasks.

These changes make it easier to keep your model aligned with the original design intent, even on complex parts.

Better control with 3D Polyline and surfacing

• The 3D Polyline tool now offers improved controls, editing, Live Transfer and export options, making it easier to define accurate paths for sweeps, pipes and reference geometry.
• Surfacing tools have been refined to better fit surfaces to your chosen patch network, helping you achieve the desired model shape more quickly and with fewer manual tweaks.

The goal is simple: let you complete as much of the reverse-engineered model as possible inside Design X, before handing off to other CAD software.

Smarter Modelling Wizards for Pipes and Sweeps

For many users, pipes, frames and tubular structures are a core part of the job. Design X 2025.1 significantly strengthens the modelling wizards in this area.

Pipe Wizard: more robust pipe modelling from real-world scans

The Pipe Wizard now delivers more accurate and robust pipe models directly from scan data, even when:

• The scan is incomplete or non-continuous
• You need to maintain tangency constraints along the pipe centreline

This makes it much easier to reverse engineer:

• Tubular frames
• Exhausts and manifolds
• Pipe runs in plant environments
• Handrails and structural members

More precise Sweep Wizard paths

The Sweep Wizard can now output the path as a 3D Polyline, giving you a more precise and editable representation of the sweep path. That path can then be used or refined in Design X or downstream CAD, improving consistency across your designs.

Seamless Integration with the Latest CAD and Scanners

A major strength of Design X has always been its ability to connect scan data with mainstream CAD tools. The 2025.1 release keeps that ecosystem up to date.

Live Transfer to the latest CAD versions

You can now continue modelling in your CAD software using Live Transfer to:

• SOLIDWORKS 2025
• PTC Creo 12
• Autodesk Inventor 2026

This means you can stay on current CAD releases without sacrificing your scan-to-CAD workflow.

Scanner Direct Control for Hexagon/ZG handheld scanners

Design X 2025.1 introduces a seamless plugin workflow with Hexagon/ZG handheld scanners, including ATLASCAN, MARVELSCAN and HYPERSCAN. You can:

• Pass scan parameters between Geomagic Design X and HHScan
• Initiate scanning from within Design X
• Send finalised scan data directly from HHScan into Design X

Fewer exports/imports, fewer chances for mistakes, and a smoother day-to-day workflow.

Improved data exchange and localisation

To round it out:

• Enhanced Data Exchange makes it easier to bring in native files from the latest CAD versions as well as Faro Scene, and to export reference geometry in standard formats.
• Russian language support has been reinstated, helping teams in Russian-speaking regions adopt the software more easily.

UI/UX Improvements for Everyday Use

Small things matter when you’re working with Design X everyday. 1 brings several UI/UX improvements, including a more robust and reliable experience with 3D mice – a welcome upgrade for power users who live on their 3D controllers.

How OR3D Can Help You Get the Most from Design X 2025.1

New features are only half the story. The real value comes from applying them to your parts, scanners and your processes.

As a Geomagic Platinum Partner, OR3D can help you:

• Plan and manage your upgrade to Design X 2025.1
• Review and optimise your scan-to-CAD workflows
• Provide training focused on the new tools (Shrink Wrap, Pipe Wizard, new mesh tools, etc.)
• Support real projects, from one-off reverse engineering jobs to full production workflows.

Whether you’re working with handheld scanners, fixed systems or importing point clouds from other software, we can help you build a robust process that takes full advantage of this release.

Ready to explore Design X 2025.1?

If you’d like to:

• See a tailored demo of the new features
• Understand how 2025.1 fits with your existing CAD and scanners
• Or get support upgrading your current environment

Get in touch with OR3D and speak to our Geomagic specialists.

We can also share Geomagic’s official launch videos and walk through how these capabilities translate into real-world time savings and better models for your team.