Paving specialists Marshalls are producing – for the first time ever - perfect replicas of historic National Trust flagstones with 3D scanning technology provided by Inition.

Inition supplied and installed a bespoke 3D scanning system capable of capturing the unique pitted and ridged surface of protected flagstones, in some of the National Trust's finest properties. The scans were used to create unique moulds for specially coloured concrete.

Marshalls approached Inition because it was not possible to remove the stones and make traditional casts. Inition built a portable scanning system capable of generating detailed scans on location. They attached a 3D laser scanner to a heavy duty tripod with a specially designed counter balance arm and hooked it all up a high power portable PC capable to enable on site data monitoring.

Each stone was scanned in great detail to ensure accuracy - between 40-50 scans per stone. Inition provided on site assistance and training during the scanning.

“At Polesden Lacy we spent 2 days scanning in the wind and the rain – not ideal conditions, but the portable system allowed us to get reliable results quickly,” said Chris Cornish from Inition.

As it was not possible to scan the edges of the stones, Inition grew artificial edges using scripts developed in house. Inition also indented the edges with the National Trust and Marshalls logo.

So far Marshalls have scanned flagstones in Lacock Abbey in Wiltshire (which was used in the Harry Potter film) and Polesden Lacey near Dorking in Surrey. The first replica stones are now available at builders merchants throughout the UK. To find your nearest stockist please visit www.marshalls.co.uk or call 0870 120 7474.

The post-scan treatment prepared the 3D scans for production. Inition first processed, cleaned and stitched the multiple images into a single dataset with INUS Technology's Rapidform Software. Then they extruded and sculpted the surface mesh in order to produce a fully 3D replica stone with matching detailing on the sides as well on the top. Finally they sent this cleaned and extruded 3D mesh to be machined and cast for production.

“Inition were a crucial part of the team from day one. We couldn’t have done it without their support and expertise,” said Vince Matthews, the new product development manager at Marshalls.

The replica stones have been entered into four sections of the annual Construction Products Innovation & Achievement review.

Notes for editors

Inition (www.inition.co.uk) was formed in 2001 by Stuart Cupit, James Gant, Chris Sutton and Andy Millns. The team has a passion for 3D graphics and provide a range of virtual reality and stereoscopic solutions, including autosteroscopic screens, bespoke interactive 3D experiences, motion capture, virtual reality hardware integration, 3D object digitizing and 3D project consultancy. Inition have worked with the RSPB, P&G, the NHS and the London Metropolitan Police

Marshalls plc (www.marshalls.co.uk) is the UK's no.1 hard landscape transformation company.Marshalls produces concrete and natural stone landscape, garden and patio products for both domestic and commercial use.