This project addresses a critical misalignment discovered on-site between the manufactured aluminium window trim (_our scope) and the freeform drywall surface (_by others). To accurately identify the source and extent of the error, we integrated a high-resolution 3D scan of the as-built condition into our digital workflow, aligning it perfectly with the theoretical model using geodetic reference points.

   Using Rhino and Grasshopper, I developed a custom analysis script to quantify the discrepancies. The algorithm populates the surface of interest with approximately 20,000 sampling points. By generating surface normals for each point, the script calculates the intersection and precise distance between the theoretical geometry and the actual 3D scan data.

   The final output is a comprehensive heat map that visualizes the deviation across the entire surface. The data is color-coded based on strict tolerance scales—ranging from green (within ±5mm tolerance) to red (deviations exceeding 25mm). This visual tool provided the team with clear, undeniable evidence of where the construction drifted from the design, facilitating a quick resolution to the interface problem.