Wilhelm Tell - Multi-Scale 3D Data Acquisition

The Challenge

A major film production for Wilhelm Tell required comprehensive 3D data acquisition across multiple scales and purposes. The project demanded:

Props digitization: ~400 set props from small handheld items to large set pieces
Crowd digital doubles: 400 extras for VFX crowd replication and enhancement
Main character facials: Detailed facial performances for principal actors

The key requirements were:

Raw data delivery: Client VFX team would handle processing internally
Multiple scanning technologies: Different subjects require specialized equipment
Time efficiency: Minimal actor engagement (max 20 minutes per session)
Production coordination: Scanning integrated into active film schedule
Data quality: Film-grade resolution and accuracy for all categories

Our Solution

We deployed a multi-pronged scanning approach, selecting optimal technology for each category while coordinating with the active production schedule.

Props: Spider Scanner + Reference Photography (~400 items)

Raw scan data computed directly from photos without any post-processing.

Spider Scanner Geometry Acquisition:

Structured light scanning for accurate geometry capture
Multiple scanning angles for complete coverage
High-resolution mesh data (sub-millimeter accuracy)
Fast acquisition suitable for production timelines
Non-contact, non-destructive scanning process

Sony A7R IV Texture Reference Photography:

61MP resolution for extreme detail
Cross-polarized capture for pure albedo information
Co-polarized capture for specular/surface characteristics
Consistent lighting setup for material reference
Color-calibrated workflow for accurate reproduction

Data Delivery:

Raw geometry data from Spider scans
High-resolution reference photographs (cross + co-polarized)
Calibration and scale information
Scanning metadata and technical notes
Client processes internally for final asset creation

Props Categories Scanned:

Small items: weapons, tools, accessories, tableware
Medium props: furniture, armor, containers, decorative elements
Large set pieces: architectural elements, wagons, siege equipment
Total: approximately 400 individual props

Crowd: Digidouble Full Body Scanner (400 extras)

Raw scan data computed directly from photos without any post-processing.

Rapid Full-Body Digitization:

Digidouble scanner captures complete body geometry + texture
360° simultaneous capture in single shot
Standing pose acquisition (1-2 seconds per scan)
Costume and wardrobe included in scan
Consistent lighting for texture uniformity

Production Integration:

On-set scanning during production days
Minimal disruption to filming schedule
Extras scanned in costume and makeup
Multiple extras processed per hour
Organized data management per performer

Crowd Scanning Workflow:

Calibration and quality checks before each session
Individual extra enters scanning volume
Single-shot capture (complete geometry + texture)
Immediate preview for quality verification
Next performer—continuous flow process

Data Output:

Raw point cloud data per performer
Full-resolution texture maps
Performer metadata (ID, costume, scene)
400 complete digital double datasets
Organized archive structure for VFX pipeline

VFX Applications:

Crowd replication and multiplication
Digital stunt doubles for dangerous sequences
Plate cleanup and performer removal/addition
Distance shots requiring digital extras
Virtual camera work in post-production

Main Characters: FACS Facial Scanning (10 expressions per actor)

Raw scan data computed directly from photos without any post-processing.

Facial Action Coding System (FACS) Capture:

Systematic capture of specific facial expressions
10 key FACS poses per main actor
High-resolution facial geometry and texture
Rapid acquisition workflow for minimal actor time
Structured data for facial rig creation

Actor-Friendly Workflow:

Maximum 20 minutes per actor session
Clear direction for each FACS expression
Immediate capture verification
Professional, efficient studio environment
Minimal makeup disruption

FACS Expressions Captured:

Neutral baseline expression
Upper face: brow raise, frown, squint
Mid face: nose wrinkle, cheek raise
Lower face: jaw drop, lip variations, smile
Combined expressions for natural range
Custom expressions per director request

Scanning Technology:

High-resolution facial scanning system
Multi-camera array for complete coverage
Structured light or photogrammetry-based
Sub-millimeter facial detail capture
Synchronized geometry + texture acquisition

Data Delivery:

Raw facial scan data per expression
High-resolution texture maps
FACS pose reference images
Actor-specific metadata
Organized by actor and expression type

VFX Pipeline Integration:

Facial rigging and blend shape creation
Performance capture retargeting
Digital face replacement
Aging/de-aging effects
Expression range expansion for animation

Project Execution

Timeline and Coordination

Props Scanning:

Coordinated with set construction and art department
Props scanned between filming use
Spider scanner deployed on-location when needed
Reference photography in controlled environment
Rolling delivery as props completed

Crowd Scanning:

Integrated into production shooting days
Digidouble scanner on-set or nearby location
Extras scanned during breaks or off-camera time
Efficient workflow: ~5-10 minutes per performer
Batch processing: 30-50 performers per day possible

Facial Scanning:

Scheduled during actor availability windows
Dedicated scanning sessions separate from filming
Professional studio environment
Quick sessions minimize schedule impact
Priority scheduling for principal actors

Quality Control

Data Verification:

Real-time preview during capture
Completeness checks (coverage, resolution)
Calibration validation before each session
Backup captures for critical subjects
Organized file naming and archiving

Technical Standards:

Film-resolution requirements met
Consistent data formats across categories
Metadata documentation
Scale and measurement references included
Client QC review at key milestones

Deliverables

Props Data Package (~400 items)

Geometry: Raw Spider scanner mesh data
Textures: Sony A7R IV reference images (cross-polarized + co-polarized)
Documentation: Scale references, scanning notes, calibration data
Format: Client-specified raw formats for internal processing

Crowd Data Package (400 performers)

Geometry: Digidouble full-body point clouds/meshes
Textures: High-resolution texture maps per performer
Metadata: Performer ID, costume notes, scene associations
Organization: Structured archive for VFX pipeline integration

Facial Data Package (Main Actors)

FACS Data: 10 expressions per actor, raw scan data
Textures: High-resolution facial texture maps
References: FACS pose documentation and images
Actor Metadata: Session notes, expression descriptions

Supporting Materials

Calibration files and technical specifications
Scanning methodology documentation
Data organization structure guide
Quality control reports

Technical Specifications

Props Scanning

Scanner: Spider structured light scanner
Geometry Resolution: Sub-millimeter accuracy
Camera: Sony A7R IV (61MP)
Reference Images: Cross-polarized and co-polarized passes
Lighting: Controlled, color-calibrated setup
Data Format: Raw scan data + high-res JPG/TIFF

Crowd Scanning

Scanner: Digidouble full-body scanner
Capture Type: 360° simultaneous acquisition
Capture Time: 1-2 seconds per performer
Texture Resolution: 4K-8K per performer
Geometry: High-density point clouds
Volume: ~400 complete digital doubles

Facial Scanning

System: High-resolution facial capture array
Expressions: 10 FACS poses per actor
Session Time: Maximum 20 minutes per actor
Resolution: Sub-millimeter facial detail
Coverage: Complete facial geometry and texture
Pipeline: Optimized for facial rig creation

Results & Impact

Production Efficiency

Minimal disruption: Scanning integrated seamlessly with shooting schedule
Actor-friendly: Quick facial sessions respected talent time
Flexible workflow: Props scanned opportunistically around set usage
High throughput: 400 crowd scans completed efficiently

Data Quality

Film-grade resolution: All data meets VFX production standards
Complete coverage: No reshoots required
Organized delivery: Structured data packages ready for client pipeline
Technical accuracy: Calibrated, measured, documented data

VFX Enablement

Raw data flexibility: Client VFX team processes to exact pipeline specs
Multiple applications: Props, crowd, facial data supports diverse VFX shots
Digital asset foundation: Scan data forms basis for extensive digital work
Future-proofing: High-resolution capture supports unforeseen needs

Multi-Scale Success

Macro to micro: From large props to facial detail
Volume achievement: 400+ props + 400 performers + multiple actors
Technology matching: Optimal scanner for each category
Coordinated execution: Complex logistics managed smoothly

Workflow Insights

Spider Scanner for Props

Structured light scanning proved ideal for props, offering:

Fast capture times suitable for production pace
Excellent geometric accuracy for hard-surface objects
Non-destructive scanning of valuable set pieces
Flexible deployment (portable to set when needed)

Combined with Sony A7R IV reference photography:

Cross-polarized captures isolate pure albedo
Co-polarized captures reveal surface characteristics
61MP resolution captures extreme detail
Gives VFX team complete material information

Digidouble for Crowd

Full-body scanner efficiency critical for large volume:

Single-shot capture eliminates lengthy sessions
Costume and character included automatically
Consistent quality across 400 performers
Integrates into production without delays

FACS for Actors

Systematic approach respects talent:

20-minute maximum protects actor schedules
Clear FACS direction ensures useful expressions
Immediate verification prevents reshoots
Professional efficiency builds actor confidence

Data-Driven Approach

Why Raw Data Delivery?

Client Control:

VFX team processes to exact pipeline specifications
Internal topology and UV layout standards maintained
Custom optimization for specific shot requirements
Proprietary tools and workflows accommodated

Maximum Flexibility:

Raw scans preserve all captured information
Processing decisions made with full shot context
Re-processing possible if requirements change
No premature optimization or data loss

Technical Advantages:

Highest quality starting point for VFX work
Complete geometric and texture information preserved
Reference data available for material authoring
Scan metadata supports multiple processing approaches

The Wilhelm Tell scanning campaign demonstrates that when diverse scanning technologies are strategically deployed—Spider for props, Digidouble for crowd, high-resolution FACS for actors—and raw data is delivered to skilled VFX teams, the result is maximum creative flexibility and technical quality for demanding film production.

Contact Us

Interested in our scanning services? Fill out the form below to request more information about our Scan Lab capabilities.