Abstract Backface deformation, a measure of the maximum deflection, is a pass/fail criterion during ballistic testing of armour plates. Traditionally, this has been measured manually but 3D scanning presents an opportunity to increase accuracy of results obtained. However, to ensure consistently accurate performance, it was necessary to develop an evidence-based procedure by which the scanner could be calibrated, BFD recorded and the relevant sources of error quantified. Research was carried out into potential technologies including laser scanning and structured light scanning. The performance of these technologies under representative conditions were compared and applied to the requirements of various standards for ballistic testing of armour plates. The effect of environmental factors on the efficiency of these technologies, such as temperature and external lighting conditions was also evaluated. Laser scanning as chosen as the most promising due its ability to provide higher accuracy scans in representative conditions of BFD measurement. A process was then mapped by which laser scanners could be calibrated, the recording media could be conditioned, and the BFD accurately measured. The process by which error attributed to the process could be calculated, was then demonstrated. Calculations that quantified laser-attributed error were discussed and shown that it consisted of three components relating to operator, repeatability, and instrument specification error. Data provided by the US Army’s Aberdeen Test Centre was obtained from a FARO scanner and the laser-attributed uncertainty for a singular scan was quantified as 0.0970mm. For joining a pre-ballistic testing and post-ballistic testing scan, to calculate the BFD, the uncertainty was quantified as 0.1372mm, within the ±0.5mm accuracy threshold suggested by the U.S. Army’s Aberdeen Test Centre.