I have been creating planes and constructing solids by pretty much building over the scanned surfaces. I know there has to be an easier way. Any advice to make these surfaces a solid would be extremely helpful.
In general the automated scan to nurbs tools can soften up details quite a bit and looking at your screenshot I would say its changed quite a bit from the original scan. It helps to generate sections from the original scan so you can be sure the detail and surfaces are not changing drastically.
This is a difficult form, and even if have SolidWorks Premium or Professional with Scan to 3d, it probably would not help get a good surfaces from this object. Scan to 3D tends to work best with more geometric types of surfaces.
I don't have Scan to 3d in my license, so I don't know if it could help you generate sections from the original scan in a point cloud or mesh format (not the nurbs surface version). It is possible to get sections of a scan as 3d lines using Cloud Compare (free) which can be imported into SolidWorks for reference.
How familiar are you with boundary surfaces, surface fills, and setting up tangencies from sketches to surfaces.?
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