3D Scanner Blog

Inspection Using a Scanner: No Reverse-Engineering Required!

There is a common misconception that, in order to inspect a part using a 3D scanner, reverse engineering is required. But this is not the case. An automated 3D scanner such as a ShapeGrabber makes the inspection process fast and simple. There is no need to reverse-engineer a 3D-model because the inspection software uses the output of the scanner directly.

 

ShapeGrabber SG Central Software lets users easily configure scan settings, speed and resolution for ShapeGrabber 3D laser scanners.

Quality control operators who use a ShapeGrabber automated 3D scanner perform an inspection simply by placing the part on the scanner turntable and clicking “Run”. The ShapeGrabber scanner automatically scans and rotates the part according to the scan specifications (for example, the density of the scan and the amount of rotation required). The scan can be conducted using default specifications or can be easily customized by the using a user-friendly interface.

 

This generates a “point cloud”—an exact representation of the entire surface area of the scanned part. This point cloud data file is easily imported into the inspection software included with the ShapeGrabber system (Geomagic® Qualify or Polyworks® Inspector). This data can be quickly compared to a reference file, such as a CAD model or the scan of a known good part, or measurements can be extracted directly from the scan data.

An inspection report is then automatically generated—with visual and numerical data—and can be saved or printed. The report quantifies the deviation of the part’s actual shape from the specifications, using GD&T analysis, error maps, tabular measurement, cross-sectional analysis, and more.

Measuring Metal Stampings with 3D Laser Scanners

It can be a challenge to inspect metal stampings, measure die wear, and ensure that specifications have been met. Traditional methods like calipers or coordinate measuring machines can fail or introduce errors that make it difficult to accurately measure the entirety of a stamped part.

To overcome these difficulties, many companies in the automotive, aerospace, computing, consumer electronics, and other industries turn to 3D scanners. An industrial 3D scanner can perform a complete inspection of a metal stamping. Unlike traditional methods that rely on the capture of a few pre-programmed points, a non-contact 3D scanner captures millions of data points and represents the true geometry of the component.

Stamped metal part: LCD screen panel

Laser scanners are ideal for metal stampings because they allow quality control staff to:

• Quickly measure the entire part and compare it to a CAD model or known good part, no matter how complex the stampings are.
• Detect die wear and other manufacturing challenges.
• Reduce human error.
• Produce automated inspection reports.

While 3D scanning is still new to some quality managers, we’ve been pioneering industrial 3D scanners at ShapeGrabber for 20 years and have seen them used effectively for the measurement of metal stampings. We can show you how a 3D scanner is:

• Is fast. You don’t need to rely on a few sample points collected with a slow CMM. 3D scanners can capture millions of data points in minutes.
• Is easy. The visual nature of the results makes it possible to quickly troubleshoot  a problem and get back to production. Moreover, you don’t need to write a computer program before scanning a part.
• Handles complex shapes. Curves and multiple features aren’t a problem for industrial 3D laser scanners. They easily scan the complex surface dimensions of metal stampings.
• Saves time & money. Parts don’t have to be placed in an expensive fixture to be scanned, leading to significant savings in capital costs. 

To learn more, we recommend these resources:

• How 3D Laser Scanners Work: A Step-by-Step Process Read >>
• Video: 3D Scanning Demonstration View >>

 

 

Improving Quality Control Processes with a 3D Scanner

One of the many benefits of a 3D laser scanner is that it is suitable in most quality control environments. In particular, a 3D scanner can enhance 100% inspection, statistical process control (SPC), and part production approval processes (PPAP).

100% Inspection Process: Enhancing Efficiencies

In the aerospace industry as an example, many parts require 100% inspection to ensure that every part shipped conforms exactly to specifications. In this environment, the volume of parts is relatively low and the impact of a failed part is very high. ShapeGrabber 3D scanners are used by a number of aerospace-parts manufacturers to increase the efficiency and coverage of 100% inspection processes.

By rapidly capturing the entire surface area of a part – including complex-shaped parts such as molded plastics or cast metals – a 3D laser scanner enhances 100% inspection with speed, and:

• An accurate measurement of the whole part can be obtained in minutes
• No special skills are required to conduct the scan
• The scanned data is quickly compared to spec via direct comparison to  CAD models, producing visual reports that show deficiencies at a glance

 

Statistical Process Control: Enhancing Data

In other situations, it may not be possible (or practical) to manually inspect each and every part off the line. Instead, manufacturers may use statistical process control (SPC). By testing a random sample of products as they leave the production line and extrapolating the results, manufacturers develop company-specific models to determine product conformance. This is a common practice in the automotive industry, for example.

Traditionally, SPC methods were tailored to devices that measure only a few points – such as gauges or coordinate measuring machines (CMMs). Most SPC models were developed more than 20 years ago, and while they have been refined over time, most do not include a 3D scanner as a source of inspection data.

Today, a 3D scanner can dramatically improve an existing SPC model by providing much more data than traditional methods. A 3D laser scanner captures a dense “point cloud” of millions of data points that represent the entire surface area of the part. 3D scanners also reduce inspection time dramatically as this data can be captured in minutes.

ShapeGrabber 3D scanners interoperate with laser scanner software that include built-in SPC capability, and that can also export the measurements for treatment by favorite SPC packages such as Minitab.  This makes it simple to implement a ShapeGrabber 3D scanner within an SPC environment. SPC can also help to identify and prevent defects early in the production process, rather than correcting problems after they have occurred.

Production Part Approval Process: Enhancing Speed

3D laser scanners can also shave time off of the Production Part Approval Process (PPAP), a standard approval process for new parts in the automotive industry. To obtain PPAP approval, manufacturers must measure a few parts many times to establish credibility. This is usually done with coordinate measuring machines (CMMs), and is typically very time consuming.

A ShapeGrabber automated 3D scanner makes quick work of this task. It not only reduces the inspection time required, but also generates more thorough results as well as automated reports.

The 3D scan data provided by ShapeGrabber scanners is also NIST-traceable.

For additional information, we recommend these resources:

•  How 3D Scanning Works – online tutorial Read >>
•  Introduction to 3D Scanning video Watch >>

 

Upgrade Your Operations in 2013 - With a 3D Scanner!

In this Industry Week article, a leading economist recommends that 2013 be the year that American business owners invest in upgrading their operations. After examining both positive global trends and risks, Alan Beaulieu concludes:

Adding to my positive outlook is the fact that virtually all of our leading indicators are pointing toward more economic expansion over the next two quarters. We can see rising trends in the ITR Leading Indicator, U.S. Leading Indicator, Purchasing Managers Index, Housing Starts and Employment. 

These signals indicate that now is the time to take advantage of pessimism and low prices. Spend some money to upgrade operations in an effort to maximize efficiency. Don't be driven by the "there be dragons" headlines; instead chart a course that meets the challenges of 2013 and takes advantage of the opportunities that will be offered.

As a critical part of manufacturing operations, Quality Control and Quality Inspection processes can be significantly enhanced by upgrading traditional, time-consuming manual measurement and inspection processes with an automated, industrial ShapeGrabber 3D scanner.

In addition to speeding quality inspection, reducing defects shipped, and thoroughly measuring and inspecting complex-shaped parts, a ShapeGrabber scanner can also support:

• Lean Manufacturing initiatives (learn how)
• Reduce the costs, time, and labour associated with using hard gauges (learn how)
• Replace or complement costly CMMs (learn how)
• Support and reduce the costs of Model-Based Design (MBD) (learn how)
• Drive down manufacturing costs (see an example)
• Become more innovative (see an example)
• ...and more.

Contact us for a cost-benefit analysis of how a 3D scanner can contribute to your operations upgrade in 2013!

 

Too Many Points to Measure? Speed up Your Quality Inspection Process with a 3D Scanner

Quality inspection processes often have to be balanced with the need for speed. Complex parts with compound curves and multiple features can be time-consuming to properly measure and inspect using traditional methods such as touch-probing, calipers, or gauges.

"Point cloud" - scan data of a plastic part produced by a ShapeGrabber 3D scanner

When products are complex, many points need to be measured, and speed is important, an automated 3D scanner such as a ShapeGrabber scanner is often the answer. Rather than having to cut corners or being simply unable to inspect some parts or points, manufacturers can use 3D scanners for thorough, rapid quality inspection. Manufacturers can:

• Reduce inspection time
• Quickly troubleshoot fit problems
• Evaluate part wear
• Measure whole parts rather than just a few points
• Minimize equipment downtime and make rapid Go/No Go decisions

A 3D laser scanner requires only a fraction of the time and resources of traditional inspection methods, yet provides thorough part coverage. The scan captures a dense “point cloud” that represents the entire surface are of the object – including curves, holes, dips, threads and other features.

ShapeGrabber’s automated 3D scanners are easy to use, as there is no need to write special code to scan each object or angle. Millions of data points are captured in minutes, the 3D part scan data can be compared to a CAD drawing or to the scan data of a known good part. This provides timely 3D measurement feedback for quality control, with automatically generated reports to prove that products are being produced to specification.

Please contact ShapeGrabber for more information or to request a sample part scan.

For additional information, we recommend these resources:

•  How 3D Scanning Works – online tutorial Read >>
•  Introduction to 3D Scanning video Watch >>

3D Scanners in Industrial Environments

Not all 3D scanners are created equal. One consideration when selecting a scanner is the nature of the environment in which it will be used.

In a manufacturing environment, an industrial 3D laser scanner - such as those we produce at ShapeGrabber - is ideal. These 3D scanners are designed to function in noisy, dusty manufacturing environments and in ambient lighting. They are also designed for use by technicians and operators rather than engineers or scientists.

Ease of Use 

In most industrial manufacturing environments, manpower is available in the form of operators and technicians. Engineering and scientific resources are less available and more costly. For rapid inspection, those functions must be "designed in". 

Because ShapeGrabber 3D scanners are designed for manufacturing environments, they are very accessible and easy to use. After only a day or two of training, an operator can quickly set scan parameters for an inspection project. Once that setup is complete, nearly any user can place a part on the scan table and simply press a button to scan the part. Software programs do not need to be written for each inspection project.

A technician placing a part in the ShapeGrabber Ai310 scanner

3D laser scanners are also simpler to use than their traditional inspection counterparts. Coordinate measuring machines (CMM) require a programmer to create a unique inspection program for each part. Calipers require specialized engineering skills to make manual measurements and calculations. Even gauges, which can be used by operators, must first be designed by engineers.

Robustness

When inspection speed is paramount, it is not efficient to have to move the inspection process to a lab or cleanroom. In addition to being easy to use, a ShapeGrabber 3D scanner is designed for use by multiple individuals. It isn’t a highly-sensitive instrument like a CMM, a fragile scientific instrument, or a shaky tripod-mounted camera assembly. It is a hardened product designed for industrial use.

Speed & Efficiency

As a mature technology (at ShapeGrabber, we’ve been pioneering industrial 3D scanners for 17 years and recently introduced our 6th generation of technology), a 3D scanner is ideal in manufacturing environments because:

• It’s fast. Lasers can capture millions of data points in minutes. The complete surface geometry of an entire part can be captured quickly to enable new or better-performing replacement products to be developed. 
• It handles complex shapes. Curves and multiple features aren’t a problem for industrial 3D laser scanners. They easily scan the complex surface dimensions of parts and tools that would otherwise be too time-consuming, costly or simply impossible to measure. 
• It saves time & money. A 3D scanner saves hours or days of inspection/measurement tasks and results in better-performing parts that reduce manufacturing errors and their associated costs. 

To learn more, we recommend these resources:

• How 3D Laser Scanners Work: A Step-by-Step Process Read >>
• ShapeGrabber Customer Story: Prosthetic Device Manufacturer Relies on ShapeGrabber for 3D Measurement and 3D Inspection of Complex-Shaped Parts Read >>

Fastest 3D Scanhead Released for Industrial 3D Quality Inspection

ShapeGrabber today announced the availability of its fastest scanhead to date. The SG156 scanhead delivers a scanning speed gain of 2 to 10 times as compared to previous models, as well as a larger sensing range and greater stability in temperature variations.

Scanhead Features

The SG156 is backward-compatible with all currently installed ShapeGrabber 3D scanners, with the addition of a new mounting bracket assembly.

Key enhancements include:

• Up to 10 times faster scanning speed than its predecessor
• Variable field of view in addition to depth of field
• Greater accuracy and tolerance to temperature changes
• Larger dynamic sensing range to scan wider range of part types
• A new mounting design allows the SG 156 scanhead to be easily installed and removed; and, provides greater precision

Customer Feedback

DENTSPLY Implants ATLANTIS division, supplier of digital implant solutions and CAD/CAM abutments, has been using ShapeGrabber scanners for more than 7 years, processing thousands
of dental models each week at facilities in Sweden and in the U.S. DENTSPLY Implants is now using the new SG156 scanhead in all its ShapeGrabber scanners.

Per Nilsson, Process Engineer at DENTSPLY Implants, Mölndal Sweden, said: “We originally chose ShapeGrabber 3D scanners for their speed, ease of use, data quality and excellent scan volume. With the new SG156 scanhead, these benefits are now magnified and support our business growth. We have reduced our average scan time, thereby increasing our output capacity while significantly reducing cost-per-scan.”

Detailed specifications for all ShapeGrabber scanheads can be found here >>

3D Scanner Technology Helps Drive Down Medical Manufacturing Costs

As numerous pressures force medical device OEMs to find cost savings, the quality control process will increasingly come under scrutiny. A significant portion of the cost in medical manufacturing lies in quality control due to the requirement to ensure 100% quality.

Quality inspection using an automated industrial 3D scanner - such as those from ShapeGrabber - is a valuable part of the solution. Fast, automated, and able to deal with the complex organic shapes that are a feature of many medical devices and parts, a 3D scanner can dramatically speed up the quality inspection process.

Incorporating a 3D scanner into quality inspection process can result in:

• Substantially reduced inspection time. Rapid automated inspection of a part's entire surface geometry is possible in a matter of minutes. ShapeGrabber's non-contact 3D scanners can measure even complex-shaped parts that have organic shapes, compound curves, and multiple features.
• 100% dimensional inspection. The entire part is measured, not just a few points, ensuring that 100% of dimensional specifications are met. A ShapeGrabber automated 3D scanner also virtually eliminates human error yet requires no special skill set to be operated.
• Improved operations efficiencies. Problems with parts can be quickly troubleshot and Go/No Go decisions rapidly made.

Additional benefits for medical manufacturers include:

• Aa 3D scanner can be used to evaluate part wear. The same part can be scanned periodically during stress- or wear-testing and the scans compared to each other to understand part wear. This article explains in detail >>
• Manufacturers can rapidly troubleshoot fit problems between parts. Read more about this >>
• OEMs can provide documented proof that they are meeting specifications, with the aid of automatically generate visual and detailed reports, and NIST-traceable scan data.

To learn more, we recommend these
resources:

• How 3D Laser Scanners Work: A Step-by-Step Process Read >>
• ShapeGrabber Customer Story: Prosthetic Device Manufacturer Relies on ShapeGrabber for 3D Measurement and 3D Inspection of Complex-Shaped Parts Read >>

 

 

 

From Manufacturing Engineering Magazine: Auto Manufacturing Focuses on Vision

Did you see Bruce Morey's article in Manufacturing Engineering Magazine, outlining the many ways - and reasons - that the automotive industry is incorporating optical metrology into its processes?

It's an excellent article! Read it here >>

...or download the PDF >> 

3D Inspection of the Inside of a Part

3D model of plastic bottle, based on 3D scan data provided by ShapeGrabber, showing cross-sections that will be measured.

Manufacturers who use a 3D scanner in their quality inspection processes sometimes need to inspect the inside of a part. In such situations, 3D scanners are used along side CT scanners.

A 3D laser scanner like a ShapeGrabber product can provide fast, accurate and radiation-free scanning of the complete external surface of a part, no matter how complex its shape. The 3D scan data can then be analysed using graphical tools such as color mapping and whisker plots, or more traditional methods such as cross-sectioning and point to point dimensioning, to obtain accurate measurements of the part.

However, no 3D laser scanner can measure the inside of a part without cutting the part to access those features. X-ray computed tomography, also known as CT scanning, can be used in conjunction with a 3D scanner when internal inspection is necessary, and it is not possible to cut the part.

Both 3D scanners and CT scanners provide non-contact
scanning. The difference is that CT scanning employs x-ray technology to capture interior features of parts, including complex or free-form shapes.

Cross-section data - plastic bottle.

These two types of scanner are often used in complement and do not replace each others’ function. For surface-scan applications where speed and accuracy are paramount, a 3D laser scanner is ideal. When internal inspection is the priority, and one is willing to compromise on speed, a CT scanner is the right choice. CT scanner operation may require  protective radiation gear (and safety training), while laser scanning has no such considerations.

Every type of 3D scanner has optimal applications and uses. Talk to ShapeGrabber about your specific inspection and measurement needs. We’ll be happy to advise you about whether a 3D laser scanner can be integrated into your quality inspection process.

For more information, we recommend:

• Article about how 3D scanners help in design prototyping: Read >>

• How 3D Laser Scanners Work: A Step-by-Step Process Read >>

• Video: 3D Scanning Demonstration View >>