From Scan to Simulation — Complete Modernization for Legacy Assets
Global Design Solutions (GDS) delivers end to end turnkey modernization for corporations and public sector clients that need to upgrade aging infrastructure, machinery, or systems.
We begin where others stop, capturing precise geometry through 3D laser scanning and carrying your project through design, fabrication, installation, and interactive digital twin visualization.
Whether you are modernizing a manufacturing plant, retrofitting an aircraft component, or rebuilding outdated infrastructure, GDS provides a single accountable partner from field to finish.
GDS turnkey modernization services cover every phase — from 3D scanning and design through fabrication, installation, and digital twin delivery.
Across every industry, aging assets and legacy equipment are holding operations back.
Original drawings are missing, replacement parts are unavailable, and downtime costs are rising. GDS helps clients modernize intelligently, preserving what works, upgrading what does not, and digitizing everything for future efficiency.
Current Market Drivers
Obsolete equipment and unavailable OEM parts
ESG and modernization mandates across industries
Safety and compliance requirements driving digital documentation
Integration of IoT, automation, and remote operations
High demand for retrofitting and reverse engineering
GDS connects the physical and digital worlds, scanning what exists, redesigning what is possible, and delivering what is next.
GDS manages the complete modernization lifecycle through a unified workflow that ensures accuracy, schedule alignment, and accountability.
We lead every phase of modernization by aligning expert teams and verified partners under one coordinated direction. Each discipline, from scanning and engineering to fabrication and installation, operates from the same precise dataset and shared project framework.
This integrated approach eliminates duplication, scope gaps, and miscommunication, resulting in a seamless delivery from concept to completion.
1. Consultation and Scoping
Define project objectives, risks, and stakeholder roles.
On site assessments, feasibility analysis, and cost mapping.
2. 3D Laser Scanning and Capture
High precision scanning of facilities, machinery, and infrastructure.
Point cloud registration and geometric verification.
3. Modeling and Design
Reverse engineering, interference checks, and fabrication models.
Multi discipline design deliverables including piping, structural, and mechanical.
4. Fabrication Coordination
Collaboration with trusted fabricators under GDS leadership for accurate manufacturing.
Quality assurance and dimensional verification prior to delivery.
5. Installation and Commissioning
Field installation, mechanical fit up, testing, and handoff.
Integration of controls, sensors, and automation components.
6. Visualization, Training, and Monitoring
Digital twin creation and immersive visualization for operations and safety.
Interactive VR and AR environments for staff training and predictive monitoring.
From consultation to commissioning, GDS provides a single coordinated workflow that eliminates rework, delays, and misalignment between teams.
Every turnkey solution is powered by aligned expertise.
GDS works closely with a network of engineers, fabricators, and installers, ensuring all disciplines operate from the same verified data and design intent.
Our coordination eliminates fragmentation and scope drift, giving clients a unified experience and a clear line of accountability from start to finish.
One direction, one dataset, one accountable partner — that is the GDS advantage.
Transform legacy machinery into digital ready systems through scan to fabrication workflows.
From conveyor lines to complex assemblies, we handle design, fabrication, and installation with precision alignment across all contributors.
Laser based design for structural frames, supports, foundations, and piping tie ins.
Deliverables include CAD models, fabrication drawings, and isometric packages for in kind or upgraded replacements.
Precise scanning and reverse engineering of airframes, assemblies, and brackets where OEM data no longer exists.
Certified fabrication, on aircraft fit up, and documentation for traceability.
Design and installation of actuators, control systems, and sensor networks that bring intelligence to older assets.
Integration with PLC, SCADA, and cloud systems for data monitoring.
Transform scanned assets into living 3D environments that mirror real world conditions.
Enable predictive maintenance, asset health tracking, and operational insight in real time.
Convert your facility’s digital twin into an immersive simulation environment for workforce training.
Operators can walk through virtual plants, rehearse maintenance, or learn safety procedures inside a precise digital replica.
Aerospace and Defense
Component retrofit, aircraft scanning, sensor modernization, and digital twin for maintenance training.
Power Generation
Turbine and casing retrofits, cooling system upgrades, and predictive monitoring via digital twin integration.
Manufacturing and Industrial Plants
Assembly line scanning, automation retrofits, and operator training through VR visualization.
Water and Infrastructure
Facility scanning, pump modernization, and structural rehabilitation visualized in 3D environments.
Oil and Gas and Energy
Piping tie ins, process upgrades, actuator installations, and real time asset twins for safety and control.
Public Sector and Transportation
Bridge and tunnel rehabilitation, mechanical retrofits, and virtual training for public works and safety operations.
If it exists in the real world, GDS can scan it, modernize it, and bring it to life digitally.
These examples illustrate how GDS turnkey services are applied across different industries and asset types.
Aircraft Retrofit
A legacy actuator is scanned, reverse engineered, and reinstalled with verified precision to extend operational life.
Power Plant Upgrade
A boiler piping system is scanned, modeled, and fabricated using point cloud data for seamless field fit up.
Infrastructure Rehabilitation
A bridge component is digitally captured, redesigned, and replaced with improved accuracy and reduced downtime.
Safety Visualization
A water treatment facility is replicated in VR for operator safety training and maintenance simulations.
Single source accountability, one coordinated partner from scan to install
Aligned expert teams, all disciplines operating under GDS leadership
Proven accuracy, verified geometric data eliminates rework
Faster turnaround, simultaneous design and fabrication workflows
Future ready data, digital twins and models built for reuse
Cross industry capability, aerospace precision in every sector
With GDS, modernization does not stop at installation, it continues in the digital layer.
Ready to modernize your assets?
Submit your project for a Turnkey Modernization Review and discover how GDS can transform your operation from physical to digital.
De-construct your world
Virtual asset assistance
Unlock your design
Infrastructure and Strategy
GDS’s Turnkey Solutions service refers to providing end-to-end modernization for aging assets or systems — taking a project from initial 3D scanning all the way through design, fabrication, installation, and digital twin visualization. It’s a comprehensive approach especially aimed at upgrading or retrofitting infrastructure, machinery, or systems, where GDS acts as a single accountable partner handling everything from field data capture to final installation.
Many industries have aging assets with missing documentation, unavailable OEM parts, and increasing downtime costs. GDS’s turnkey modernization addresses these by preserving what works, upgrading what doesn’t, and digitizing everything for future efficiency — overcoming issues like obsolete equipment, sustainability mandates, safety compliance requirements, IoT and automation integration, and high demand for retrofits.
GDS leads every phase in a unified workflow: Consultation and Scoping (define objectives, risks, on-site assessment); 3D Laser Scanning and Capture (high precision scanning, point cloud registration); Modeling and Design (reverse engineering, interference checks, fabrication models); Fabrication Coordination (GDS oversight, quality checks before delivery); Installation and Commissioning (field installation, mechanical fit-up, controls integration); and Visualization, Training and Monitoring (digital twins and VR/AR for operations and ongoing monitoring).
GDS aligns all expert teams and partners under one coordinated plan — one direction, one dataset, one accountable partner. This means everyone (scanning team, engineers, fabricators, installers) works off the same precise data and design intent, eliminating fragmentation or scope drift. The client does not have to manage multiple vendors or worry about data translation errors; GDS is accountable for the full outcome.
Core offerings include: Industrial Retrofits (scanning and modernizing legacy machinery); Civil, Structural, and Piping Systems (laser-based design for frameworks, supports, and piping tie-ins); Aerospace and Automotive Retrofitting (scanning airframes and assemblies, fabricating certified parts); Actuator, Sensor, and IoT Integration (adding modern control systems to old assets); Digital Twin Implementation (making a digital twin for maintenance and asset health tracking); and Software Visualization for Training and Safety (VR simulations for workforce training).
GDS serves multiple industries: Aerospace and Defense (component retrofits, sensor modernization); Power Generation (turbine and cooling retrofits with digital monitoring); Manufacturing and Industrial Plants (assembly line scanning, automation retrofits, VR training); Water and Infrastructure (facility scanning, pump modernization, structural rehab); Oil, Gas, and Energy (piping tie-ins, process upgrades, real-time asset twins); and Public Sector and Transportation (bridge and tunnel rehab, virtual training for public works).
Yes — Aircraft Retrofit: scanning an actuator, reverse engineering it, reinstalling a precise replacement to extend life. Power Plant Upgrade: scanning a boiler piping system, modeling it, fabricating replacement spools that fit perfectly via point cloud data. Infrastructure Rehabilitation: scanning a bridge component, redesigning it digitally, and replacing it with improved accuracy and reduced downtime. Safety Visualization: creating a VR model of a water treatment plant for operator safety training and maintenance simulations.
Clients choose GDS because of single source accountability — GDS is the one coordinated partner from scan to install. This means less hassle managing multiple vendors and clear responsibility; if something is off, GDS fixes it. Their integrated approach ensures things are done right the first time, saving time and money. GDS provides precision, holds to schedules, and covers all bases — design, checks, fabrication oversight — which is critical for complex projects.
GDS explicitly addresses ESG mandates by upgrading to more efficient technology, safety and compliance by documenting digitally, IoT and automation by integrating sensors and control systems into old equipment, and the demand for retrofitting by having the capacity to reverse engineer and fabricate needed parts. Their services align directly with the pressures companies face to update old systems to modern standards — reducing emissions, adding automation, and ensuring safety compliance.
Start with a consultation where GDS discusses objectives and does an on-site assessment. GDS then presents a plan covering scanning, design, cost, and timeline. Once agreed, GDS mobilizes scanning teams, then design teams, and coordinates fabrication — managing schedule and deliverables at every stage. The client is updated at major milestones. GDS delivers a finished, installed solution along with digital documentation — models and digital twins — at the end.
