Deutsche Bahn: From Manual 3D Modeling to a Digital Twin Foundation

• BIM models too rigid and time-consuming for existing facilities
• Manual modeling inconsistent and impossible to scale across thousands of sites
• 3D data disconnected from SAP and maintenance management systems
• Technical bottlenecks limiting access to spatial data across teams

• Automated mesh generation from any point cloud or 360° capture source
• Consistent, scalable 3D models deployable across DB’s entire network
• Direct integration with SAP PM and Revit through open connectors
• Any stakeholder can access, measure, and collaborate via web browser

Deutsche Bahn manages one of Europe’s largest and most complex infrastructures—thousands of stations, facilities, and assets that require constant maintenance, inspection, and modernization.

DB Systel GmbH is a wholly owned subsidiary of DB AG and the driver of digitalisation for all Group companies. With its holistic offering, the company drives the digitalisation of business processes and rail-specific digital solutions, creating excellent customer experiences with strong customer benefits. To achieve its vision of a scalable 3D foundation for every station, DB Systel’s Immersive Technology team needed a consistent, cost-effective way to turn real-world conditions into usable 3D environments.

What followed was a scalable 3D digital twin program that cut on-site time, connected spatial data to SAP PM, and gave maintenance and operations teams a virtual window into every station on the network.

The Challenge: Turning Data into Usable Reality

DB Systel GmbH explored several methods to create accurate 3D representations of its stations and facilities, but each fell short of delivering the consistency and scalability required.

• BIM models were too rigid and time-consuming for existing facilities—teams couldn’t easily update or validate changes.
• Manual modeling efforts using photo references were inconsistent and costly, making it difficult to scale across DB’s vast network.
• Fragmented workflows made it difficult to link 3D data to operational systems like SAP and maintenance management tools.

We had the data, but not the means to make it usable at scale

— Jonas Heidecke, Requirements Manager, DB Systel GmbH

The Solution: Prevu3D’s Scan-to-Mesh Engine

DB Systel GmbH partnered with Prevu3D to address the core technical challenge—automating the transformation of raw scan data into a solid, scalable, and interoperable 3D model.

Using RealityPlatform™ Digital Twin Software, DB Systel GmbH can now:

• Ingest point clouds and 360° captures from LiDAR, SLAM, or photogrammetry sources.
• Automatically generate meshes that are lightweight, accurate, and instantly viewable through a web browser.
• Connect the visualization to SAP PM and other enterprise systems through an open API framework.
• Enable non-technical users—from facility managers to maintenance staff—to visualize, measure, and collaborate in real-time.

Changes due to repair measures, conversions, and redesigns can be easily implemented in 3D visualization.

— DB Systel GmbH, Facility Management Workshop (BIM to Operations Program)

This confirmed that the Scan-to-Mesh workflow could flexibly adapt to real-world change, turning static scans into living, updatable models that scale across DB’s network.

Results: From Proof-of-Concept to Platform Strategy

Through functional testing conducted jointly between DB Systel GmbH and Prevu3D, DB confirmed key hypotheses:

• 3D visualizations can be easily kept up-to-date.
• Repair measures, conversions, and redesigns can be implemented directly in the 3D environment.
• On-site visits are reduced, accelerating maintenance and inspection workflows.
• Data from SAP PM is now more accessible to all stakeholders through visual context, improving both usability and data quality.

For facility management, the question is no longer whether to use 3D visualization, but how to use it effectively.

— DB Systel GmbH, Immersive Technology – Reality Capture

These results have solidified 3D visualization as a foundational element of DB Systel GmbH’s facility management strategy, with measurable improvements in efficiency across core processes including inventory data collection, on-site briefings, and construction-to-operation handovers.

Why It Works

Prevu3D’s strength lies in unifying data fidelity with usability while delivering the scalability needed to support enterprise-wide deployment.

• The Scan-to-Mesh pipeline eliminates the bottleneck of manual modeling, enabling DB Systel GmbH to process large volumes of scan data with consistent quality.
• The Prevu3D ecosystem provides both the technical and operational layers DB Systel GmbH needed: automated meshing, RealityPlan editing tools, and seamless web-based access.

• Integration with systems like SAP PM and Revit ensures 3D data isn’t isolated but becomes part of the broader digital operations ecosystem.
• Data democratization: RealityPlatform™ empowers every user—whether in the field or the office—to access, measure, and collaborate in 3D. It requires minimal training, runs on standard PCs, and can be easily shared across teams or external partners.

Looking Ahead

With RealityPlatform™ now integrated into its 3D visualization initiative, DB Systel GmbH is expanding the Scan-to-Mesh workflow across more stations and facility types. The next phase centers on connecting 3D environments more deeply into the building lifecycle—linking planning, construction, and operations through BIM and SAP PM.

Key Benefits at a Glance