3D Scanner Blog

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!

 

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 >>

 

 

 

Benefits of Measuring & Inspecting Medical Parts with a 3D Scanner

Medical device components, such as implants and prosthetics, pose a number of challenges for manufacturers. In addition to being highly complex, they need to be extremely reliable for use in human patients. Moreover, some medical devices are custom “one-of-a-kind” parts with very specific measurements for an individual patient.

 

Components like this knee implant, made by DePuy Orthopaedics (shown implanted inside the human body in the X-ray), are checked with laser scanning, because of the complex sculptured contours required for proper functioning.

Automated 3D laser scanners like those from  ShapeGrabber help companies to quickly measure complex-shaped medical parts, including parts with compound curves. Unlike traditional methods (like calipers or coordinate measuring machines) that rely on the capture of a few pre-programmed points, a non-contact 3D scanner captures 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 used with software for measurement, and direct comparison to the CAD model. Using a 3D scanner, manufacturers of medical components can:

• Reduce inspection time
• Ensure that 100% of dimensional specifications are met
• Troubleshoot fit problems between parts
• Automate the inspection process
• Provide documented proof that they are meeting specifications

 

DePuy uses a ShapeGrabber Automated 3D scanner like the one pictured above.

As a mature technology (at ShapeGrabber, we’ve been pioneering industrial 3D scanners for 19 years), 3D laser scanning is ideal for medical device manufacturers for the following reasons: 

 

• It’s fast. Lasers can capture millions of data points in minutes. The complete surface geometry of an entire part can be captured quickly. 
• 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 parts.

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 >>

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 >>

Closing the Quality Loop through 3D Measurement & Inspection

In this Quality Digest article, Donald Jasurda correctly observes of today's quality environment:

"The focus of manufacturing quality has shifted to a discussion about the cost of quality and how to manage it. The manufacturer that can minimize the cost of quality while producing products the fastest, is the one that will win in today’s market."

The article focuses on “closed loop” quality management from a dimensional analysis perspective. In broader terms, closed-loop quality management involves the ongoing collection and evaluation of data from all parts of the manufacturing process to identify potential problems before quality issues arise. Virtual simulations and tolerance analyses are some of the tools used in this approach.

3D Scanners: A Natural Fit in Closed-Loop Quality Management

ShapeGrabber Ai810 automated 3D scanner with plastic part on scanning table

For an organization with closed-loop quality management practices in place, an automated 3D scanner is a natural fit in the quality process. Specifically, 3D scanning can be integrated into the quality inspection process to provide dimensional measurement and analysis of parts as they are manufactured.

Jasurda lists eight steps involved in a closed-loop quality management process. Data produced by automated 3D scanners, such as those manufactured by ShapeGrabber, enables a number of those steps to be integrated into the quality inspection process. These include:

1. Analyze tolerances. Complete 3D data of entire parts can be captured in minutes and fed into the closed-loop process for evaluation, tolerance analysis, decision-making and revision as required.
2. Generate dimensional data. The 3D scanner generates accurate three-dimensional data of a given part’s entire surface area. The automatically generated reports can be stored for future reference.
3. Conduct root cause analysis. 3D scan data supports quality engineers in isolating common quality problems and identifying their cause – such as mold wear, thermal and pressure settings and so on.

The author summarizes the cost benefits of these steps:

“By relying on virtual simulations throughout this process and feeding measurement inspection data back into the tolerance model, engineers can quickly pinpoint issues and perform corrective actions—avoiding the need to chase problems through their build processes by trial and error. This saves direct and indirect costs required to achieve quality goals.”

An automated 3D laser scanner further extends the scope of this process to reach into the quality inspection arena.

Achieve Best-In-Class Quality Inspection with Automated 3D Laser Scanners

This Aberdeen Group report on closed-loop quality management identifies the top goals of quality managers today. 3D scanning in the quality inspection process contributes directly to the top two of those goals:

1. Ensure customer satisfaction. Once a production part is scanned with an automated  3D laser scanner, it is easily compared to CAD data, and the easy-to-understand, visual reports demonstrate to the customer that parts are meeting spec.  
2. Reduce the total cost of quality. Automated 3D scanners provide a dramatic improvement in efficiency over traditional methods of measurement, such as calipers or touch-probe CMM tools. Automation both reduces the total cost of quality and makes it possible for quality inspection processes to provide greater coverage – scanning more parts faster, or scanning parts that were previously impossible to measure due to complexity of shape or material type.

ShapeGrabber 3D scan data compared to CAD model using Polyworks(R) software

3D scanning also supports one of the top two best-in-class strategies that Aberdeen Group identifies: continuing to improve operator effectiveness by delivering critical quality data from across the enterprise. With comprehensive, accurate 3D scan data, operators are able to quickly detect and isolate quality problems such as warpage, twist, fit, and die wear. They can rapidly compare the data to known good parts, designs or prototypes. They can easily produce automatic inspection reports to share with customers or other experts. And, they can use the data to make rapid go/no-go decisions.

Another group of attributes of “best-in-class” manufacturers that Aberdeen Group identifies relate to defect rates. Those manufacturers who are top in quality average 31% fewer defects per million; spend 29% less on internal failures; and spend 60% more on defect prevention. Once again, a 3D scanner can contribute to developing such leading practices, and has been shown to reduce defects-shipped rates. For example, a ShapeGrabber 3D laser scanner helped this mold maker to resolve a specific persistent problem of error rates on the floor.

Automated 3D Laser Scanners Help Close the Quality Loop

For manufacturers focused on improving customer satisfaction, reducing the total cost of quality, and minimizing defects-shipped, an automated 3D laser scanner can contribute directly to quality management goals and best practices. They are particularly valuable in situations where complex-shaped parts (compound curves, multiple features) are otherwise too time consuming, costly, or simply impossible to measure.

If complex-shaped parts are leaving holes in your closed-loop quality management practices, contact ShapeGrabber for a free part scan or to learn how an automated 3D scanner capability can improve your quality inspection program.

 

3D Laser Scanning: Solving the Toughest Quality Inspection Problems

Manufacturers come to us with many different complex parts in a variety of sizes and materials, but one problem arises frequently: “I can’t figure out why this part is coming out off spec!”

The reason is that traditional inspection equipment – such as manual caliper and micrometer measurements, or touch-probing with a coordinate measuring machine (CMM) or vision system – do not provide enough information to allow effective troubleshooting. These tools may take too long, require expert resources that aren’t readily available, or simply can't handle very complex shapes. It may be difficult or impossible to obtain dense enough coverage of the part to inspect and identify tough problems. These methods may provide some answers about why a part is not meeting spec but not the whole picture. 

Although industrial 3D scanning technology is robust – at ShapeGrabber we’ve been developing it for 19 years over 5 generations of technology – the use of 3D scanning for quality inspection is relatively new. But today, inspection is quickly becoming the number-one application for 3D scanners.

To inspect complex shapes, a 3D laser scanner offers two main benefits:

• It’s fast. A ShapeGrabber 3D scanner can capture millions of data points in minutes. The surface geometry of an entire part can be captured quickly then inspected, measured, compared and decisions made.
• It handles complex shapes. Curves and multiple features aren’t a problem for industrial 3D laser scanners. They scan complete shapes that would otherwise be too time-consuming, costly or simply impossible to measure. 

The 3D scanner outputs a point cloud, which is essentially a complete map of the part’s surface geometry. This can be compared directly to the 3D CAD model to quantify the deviation of the part’s shape from specifications.

The resulting full-color deviation maps have helped countless users to quickly identify the specific part areas that are out of spec – and eliminate their most nagging quality control headaches! Because the amount of 3D scan data is so great, it is possible to use rich and graphical tools to analyze the data, making troubleshooting intuitive: very subtle defects can be easily seen.

Sample deviation map comparing actual part (3D scan data) to 3D model

3D scanning is known to effectively troubleshoot tough issues such as warpage, twist, voids, fit, die wear, mold manufacturing deficiencies and more. It improves quality inspection efficiencies by enabling rapid Go/No Go decisions. It increases production yields, reduces production time and defects shipped.

This short video demonstrates the process, from the scanning to the dimensional output: http://shapegrabber.com/fla/ai310-quick-demo/ai310-scanning-demonstration.html.