3D Scanner Blog

Part Replication with Laser Scanning

At some point, most manufacturers will need to replicate a part for which there is no original CAD file. Perhaps it’s a tool nearing the end of its life, a legacy part that was designed in the pre-CAD days, or a component that was modified after the CAD model was created.

3D laser scanning offers a fast and accurate way to create a complete digital 3D model of even the most complex part to aid in modeling and replication. Unlike calipers, gauges, or coordinate measuring machines that rely on the capture of a few pre-determined points, non-contact 3D laser scanners capture millions of data points to represent the true geometry of an existing component.

A 3D scanner captures a dense “point cloud” that represents the complete surface area of the part. This data can be sent directly to CAD software to be measured, manipulated and replicated. With a complete 3D model of the part or object, you can:

• Obtain CAD models of legacy parts or tools reaching end of life
• Develop new or better-performing replacement products based on the physical properties or shape of the existing part
• Update CAD models of your part, model, tool or die to match post-prototype modifications

3D laser scanning is a mature technology that is especially useful in replication projects because:

• It saves time & money. A 3D scanner saves hours or days of inspection/measurement tasks and results in better-performing replacement parts that reduce manufacturing errors and their associated costs.
• It handles complex shapes. Laser scanners easily scan the complex surface dimensions of parts and tools that would otherwise be too time-consuming, costly or simply impossible to measure. Curves and multiple features aren’t a problem!
• It’s easy. You don’t need to write a computer program before scanning a part.
• It’s proven. At ShapeGrabber, we’ve been pioneering industrial 3D scanners for 17 years!

To learn more, we recommend these resources:

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

Video: 3D Scanning Demonstration View >>

Achieving Cost-Effective Model-Based Design with a 3D Scanner

- Pierre Aubrey, CEO, ShapeGrabber

 

Pierre Aubrey, CEO

For many original design and equipment manufacturers (OEMs/ODMs), model based design (MBD) is becoming a favoured method to flow requirements to their manufacturing suppliers. But it may be difficult for many manufacturers to support while maintaining promised lead times and keeping prices competitive. But, 3D scanning provides an answer to this conundrum.

 

How MBD Works

In MBD, the 3D model itself, along with tolerances relating to the model, contain the requirements definition for the part or product. This approach is in contrast to the traditional method, in which the 3D model was used as information only and the primary requirements were contained in accompanying two-dimensional drawings.

Challenges of MBD

MBD works very well with modern manufacturing equipment and in environments with 3D CAD/CAM technologies. However, it creates challenges for companies using 2D-based inspection process and equipment. Because these companies rely exclusively on the 2D drawings for requirements information, problems can arise when:

• Variances exist between the 3D model and the 2D drawings
• The 2D drawings are incomplete (as is often the case, since the 2D drawings are not as central to the design)

Dealing with these challenges adds time and cost to the inspection process, and discrepancies between 2D and 3D information can lead to errors. While manufacturers may be under pressure from their customers to accommodate MBD – or may wish to introduce MBD as a competitive advantage – they cannot do so if it increases costs, lead times, or diminishes quality.

The Solution: 3D Scanning

The solution is 3D scanning. 3D scanning used as part of the quality inspection process can resolve all of the challenges described above because the inspection process compares 3D scan data of the actual part directly to the 3D model. In this way, introducing rapid, automated whole-part scanning into the quality process with a 3D scanner improves inspection accuracy at the same time.

You can contact ShapeGrabber for more information about introducing 3D scanning as a competitive differentiator in your manufacturing process.

 

 

3D Inspection for Design

3D scan data (point cloud) of a radiator tank, captured by a ShapeGrabber 3D scanner.

In this blog, we've often discussed the benefits that 3D laser scanning brings to post-production activities ,such as quality inspection and modeling. But 3D scanning can also be used during the product design process to complement 3D modeling and CAD systems.

Laser scanners are useful tools for scanning prototypes and products under development because they can very rapidly capture the entire surface area of a part, and multiple scans can clearly show even subtle differences between prototype iterations.

Unlike traditional methods of measurement (like calipers or coordinate measuring machines) that rely on the capture of a few pre-programmed points, a non-contact, automated 3D laser scanner captures millions of data points to validate the complete geometry of an existing component. 

By validating a part’s complete geometry, designers can quickly identify problems – such as form and fit issues on mating parts – and use the data to improve the manufacturing process and reduce the complete design life cycle. This also facilitates feedback throughout the design process.

The ShapeGrabber Ai310 automated 3D scanner.

3D scanners capture a dense “point cloud” that represents the complete surface area of even the most complex part. That data can be brought into nearly any leading 3D modeling software tool to help designers to design, visualize and tweak new products by innovating beyond traditional boundaries and limitations found in design and CAD software. It also makes it easier to quickly verify, render and compare new product designs as well as troubleshoot the entire manufacturing process.

A 3D laser scanner can enhance the design process in these ways:

• Design unique products: Innovate beyond traditional boundaries and limitations found in design and CAD software.


• Gather design feedback: Examine accurate 3D part models to gather accurate and timely feedback on your prototypes.


• Rapidly verify, render, and compare new product designs.


• Troubleshoot your manufacturing process to reduce the length of the design cycle.

3D laser scanning is also appealing 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 speed troubleshooting and reduce the length of the design cycle. 
• It handles complex shapes. 3D laser scanners can easily scan the curves and complex surface dimensions of parts and tools that would otherwise be too time-consuming, costly or simply impossible to measure.This makes it ideal for parts being designed in the most innovative plastics and resins, for example. 
• It’s easy. You don’t need to write a computer program before scanning a part. 

To learn more, we recommend this resource:

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

Small Industrial Applications of 3D Scanning: Video

This video demonstrates how 3D laser scanners can be used to quickly capture the entire surface geometry of small parts in industrial settings.

View it now >>

3D Metrology vs. Machine Vision: Understanding the Differences

When researching a dimensional quality control solution, it is important to understand the difference between 3D scanners and machine vision systems. While both types of equipment are used in quality control, they are used to achieve different results.

3D Metrology

3D Metrology (or measurement) is the science of measurement in three dimensions (x, y, z). 3D measurement is often used in quality inspection - for example:

1. Manual measurement. Skilled human operators use calipers and gauges to take the required measurements of a manufactured part at specific points on its surface.
2. CMM (coordinate measuring machine). Like an automated caliper, a CMM uses touch-probe sensors to measure the required surface area of an object.
3. 3D scanners. Using light (such as lasers) rather than contact, the complete surface of an object is scanned in seconds at one time to obtain a dense “point cloud” of the object’s surface area. 

Machine Vision

An example of machine-vision in action.

Machine Vision is a broad term describing a process that applies a variety of technologies - including  imaging - to a wide range of tasks. Some of those tasks may include measurement, but many do not.

For example, a machine vision system may be used to inspect manufactured products for defects such as surface blemishes or improperly applied caps or labels. They may be used to compare package sizes, sort packages, read barcodes, guide robots, and so on. These systems are typically custom-designed, or configured to perform a very specific set of inspection tasks.

Traditionally, machine vision systems are used to acquire and analyze two-dimensional (2D) images of manufactured products. 

3D Scanners

By using methods such as triangulation and light pattern projection, machine vision can be used to create a 3D digital representation of a physical object. If the 3D representation is dimensionally accurate, it can be called a metrology-class 3D scanner, such as a ShapeGrabber 3D scanner. Metrology-class 3D scanning is particularly effective for quality inspection of parts that have complex shapes, compound curves and multiple features. 

Example of 3D Scanning & Machine Vision Together

To fully understand the unique strengths of 3D measurement and machine vision, we'll use the example of a product comprising two different plastic parts that are joined together.

A machine vision system could be placed beside or over top of the production line, capturing 2D images of the parts as moved along a conveyor belt. The system could be custom-designed to identify if any of the products had a faulty joint, and may be programmed to send instructions to other robots or human operators to remove the part or, in severe cases, to stop the line.

The ShapeGrabber Ai310 Automated 3D Scanner

A 3D scanner would be used offline to determine the cause of a recurring problem such as a faulty joint. The surface area of problem parts would be quickly scanned, brought into specialized software such as Polyworks Inspector or Geomagic Qualify, then compared to the part’s CAD model (or the scan of a known good part) to isolate the fit problem and investigate the cause (e.g. mold wear, warpage, twist, etc.).

When selecting the right 3D scanner for your needs, it is also helpful to understand the differences between white-light scanners and laser scanners. Read the white-light versus 3D laser scanner article >>

Optical 3D Scanning: Laser Beam or Structured Light?

Optical 3D scanners can be generally categorized into two technological groups: those that use lasers and those that use structured light (also called white light scanners). Both technology platforms can be used to render accurate 3D models of the surface area of objects more quickly and thoroughly than calipers or automated touch-probe methods like coordinate measuring machines (CMMs).

All 3D scanners are designed to render the actual surface area of an object into electronic form known as a “point cloud”. When the light hits the object and is reflected back to a camera, a measurement is taken that calculates depth. When tens or hundreds of thousands of these measurements are taken per inch of object, the resulting scan data provides a picture of the part’s shape. The scan data can then be used to create CAD, CAM or CAS models, or can be compared to existing models to identify deviations between an actual part and the model – or deviations between two parts.

Lasers emit light through optical amplification (photons are stimulated to achieve greater reach). They are precise and reliable because they have a high degree of spatial and temporal coherence compared to other technologies. This means that lasers can emit very small, precisely focused beams that travel a relatively long distance.

A 3D laser scanner shines a laser beam onto the surface of an object, and the reflection of that beam on the object’s surface is captured by a camera. The laser may be directed in a single line or as a plane (as shown in the photo to the right). Through a process of triangulation, the distance of each surface point measured is recorded and collated to obtain a thorough 3-dimensional rendering of the object’s shape and surface measurements. (This online tutorial from Innovmetric provides a detailed explanation of this process).

Structured light scanners use a “white light” source such as halogen or LEDs to project a pattern (like a blanket) of pixels that deforms when it strikes the target surface. A 3D reconstruction of the object is created from measurements based on the deformations of the light pattern.

When determining the best type of optical 3D scanner for a job, the following factors can be considered:

	Advantages	Disadvantages
Laser Scanner Method	Can be used in virtually any indoor lighting condition Can be used to scan parts of any material, colour or luster Provides excellent depth resolution to measure detailed features, compound curves, cracks, etc.	“Speckle” effect poses limitations on resolution and accuracy Laser light should be used with precautions (lasers should not be shone into eyes)
White Light Scanner Method	Provides good accuracy Fast when measuring objects with many low-curvature surfaces Good lateral resolution along two axes Eye safe	Sensitive to ambient light – best used in darkened room Cannot be used to scan shiny surfaces “Occlusion” effects require the need for additional images to be taken Slow when measuring objects with many intricate details
This comparison is adapted from Innovmetric’s “3D metrology hardware review”

Every 3D scanner – even within a single manufacturer’s product portfolio – has a unique spectrum for accuracy and data quality. For that reason, more than one scan method may be useful in the manufacturing environment. For example, ShapeGrabber’s automated 3D laser scanners are often used in quality control environments in conjunction with white light scanners. ShapeGrabber can be used to rapidly measure part conformance every minute or two, while a skilled operator in a dark room simultaneously uses a white light scanner to conduct more detailed analyses offline.

At ShapeGrabber, we help manufacturers determine the best scanner for their applications by assessing the nature and volume of the parts to be scanned and the requirements for accuracy, automation, resolution, portability and more. For manufacturers with suitable parts, we provide a sample part scan 3D scan report to demonstrate the best combination of accuracy and speed that can be achieved with one of our 3D laser scanners.

If you are weighing your 3D scanning (or CMM) options, please contact us to request a complimentary 3D part scan!

To see the technical principles behind how ShapeGrabber Scanners operate, please watch the video: Principles of 3D Measurement using Laser Light

 

 

The Creative Side of 3D Scanning

ShapeGrabber was pleased to be involved in the RAPID 2012 conference in Atlanta last week. We were busy bees, chairing a technical session and giving a 3D scanning workshop. Our business focuses on industrial part inspection, but all kinds of applications of 3D scanning and 3D modeling are represented at this show.

A blogger, Fabbaloo, has captured some very nice photos of some of the more artistic, unusual, and creative 3D forms seen at the event - check them out here: http://fabbaloo.com/blog/2012/5/25/around-the-show-floor-at-rapid-2012.html

Reverse Engineering with Laser Scanning

It’s a common product development challenge: you need to replicate a part, mold or tool but don’t have the original CAD files. Or, you may have a prototype that includes post-design modifications that aren’t reflected in the original spec.

3D laser scanning offers a fast and accurate way to create a complete digital 3D model of even the most complex part to aid in reverse engineering. Unlike traditional methods (like calipers or coordinate measuring machines) that rely on the capture of a few pre-programmed points, a non-contact 3D laser scanners captures millions of data points to represent the true geometry of an existing component.

The 3D scanner captures a dense “point cloud” that represents the complete surface area of the part. This data can be sent to CAD or directly to CAM software to be measured, manipulated and replicated. With a complete 3D model of the part or object, you can:

• Develop new or better-performing replacement products based on the physical properties or shape of the existing part
• Update CAD models of your part, model, tool or die to match post-prototype modifications
• Obtain CAD models of legacy parts or tools reaching end of life

As a mature technology (at ShapeGrabber, we’ve been pioneering industrial 3D scanners for 17 years), 3D laser scanning is popular for reverse engineering projects 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’s easy. You don’t need to write a computer program before scanning a part.
• It saves time & money. A 3D scanner saves hours or days of inspection/measurement tasks and results in better-performing replacement 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 >>
• Video: 3D Scanning Demonstration View >>

 

Bringing Prototypes to Life with Laser Scanning

This blog post has been updated and can now be found here: Bringing Prototypes to Life with a 3D Laser Scanner.

Supporting Cost-Effective Model-Based Design (MBD) with 3D Scanning

- Pierre Aubrey, CEO, ShapeGrabber

For many original design and equipment manufacturers (OEMs/ODMs), model based definition (MBD) is becoming a favoured method to flow requirements to their manufacturing suppliers. But it may be difficult for many manufacturers to support while maintaining promised lead times and keeping prices competitive. But, 3D scanning provides an answer to this conundrum.

How MBD Works

In MBD, the 3D model itself, along with tolerances relating to the model, contain the requirements definition for the part or product. This approach is in contrast to the traditional method, in which the 3D model was used as information only and the primary requirements were contained in accompanying two-dimensional drawings.

Challenges of MBD

MBD works very well with modern manufacturing equipment and in environments with 3D CAD/CAM technologies. However, it creates challenges for companies using 2D-based inspection process and equipment. Because these companies rely exclusively on the 2D drawings for requirements information, problems can arise when:

• Variances exist between the 3D model and the 2D drawings
• The 2D drawings are incomplete (as is often the case, since the 2D drawings are not as central to the design)

Dealing with these challenges adds time and cost to the inspection process, and discrepancies between 2D and 3D information can lead to errors. While manufacturers may be under pressure from their customers to accommodate MBD – or may wish to introduce MBD as a competitive advantage – they cannot do so if it increases costs, lead times, or diminishes quality.

The Solution: 3D Scanning

The solution is 3D scanning. 3D scanning used as part of the quality inspection process can resolve all of the challenges described above because the inspection process compares 3D scan data of the actual part directly to the 3D model. In this way, introducing rapid, automated whole-part scanning into the quality process with a 3D scanner improves inspection accuracy at the same time.

Please contact ShapeGrabber for more information and to discuss introducing 3D scanning as a competitive differentiator in your manufacturing process.