This paper examines how digital scanning techniques can be utilised in the digital fabrication of hybrid materials. It explores how ‘imperfections’ discovered in natural materials can inform unique design solutions. In the first part of this paper, the technical scan-to-production process is explained. Secondly, the paper discusses this new production model against current standardised production processes. Third, the paper introduces ways in which the proposed research method can be incorporated into emerging design practices through three realised projects – Digitized Grain, STP @ Milano Design Week, and Timber X-Ray Scanning; Finally, an assessment of the Research through Design Production over the course of these projects details the key changes in each stage of the STP process.