AN INTRODUCTION
TO 3D SCANNING
While the mainstream media continues its obsession with 3D printing, another quiet, perhaps
more impactful, disruption is revolutionizing the way products are designed, engineered, manufactured, inspected and archived. It’s 3D scanning -- the act of capturing data from objects in
the real world and bringing them into the digital pipeline.
ACCORDING TO A RECENT STUDY
BY MARKETSANDMARKETS, THE
3D SCANNING MARKET WILL GROW
NEARLY
15%
ANNUALLY OVER THE NEXT FIVE
YEARS, WITH THE
PORTABLE 3D SCANNING SEGMENT
LEADING THE WAY.
Portable 3D scanning is fueling the movement
from the laboratory to the front lines of the
factory and field, driven by the following key
factors:
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3D scanners are tri-dimensional measurement devices used to capture real-world objects or
environments so that they can be remodeled or analyzed in the digital world. The latest
generation of 3D scanners do not require contact with the physical object being captured.
Real Object
3D Model
3D scanners can be used to get complete or partial 3D measurements of any physical object. The majority of these devices generate points or measures of extremely
high density when compared to traditional “point-by-point”
measurement devices.
OBJECTS ARE USUALLY
SCANNED IN 3D FOR
2
PURPOSES:
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Reverse engineering
GEOMETRICAL
ENTITIES
MESH
CAD
PART
3D
COMPARISON
SCAN
2D
COMPARISON
Inspection
There are TWO major categories of scanners based on the way they capture data:
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Scanning results are represented using free-form, unstructured three-dimensional data, usually in the form of a point cloud
or a triangle mesh. Certain types of scanners also acquire color information for applications where this is important.
Images/scans are brought into a common reference system, where data is merged into a complete model. This
process -- called alignment or registration -- can be performed during the scan itself or as a post-processing step.
Point Cloud
Triangle mesh
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The resulting triangle mesh is typically exported as an STL (STereoLithography or Standard Tessellation Language)
ÀOHRUFRQYHUWHGWR1RQ8QLIRUP5DWLRQDO%6SOLQH 185%6) surfaces for CAD modeling.
Triangle Mesh exportable
in STL format
Converted to
NURBS surfaces
THE BENEFITS AND LIMITATIONS
OF A 3D SCANNER ARE TYPICALLY
DERIVED FROM ITS POSITIONING
METHOD. THAT’S WHY IT IS VALUABLE
TO TAKE A LOOK AT POSITIONING
METHODS WITHIN THE DIFFERENT 3D
SCANNER CATEGORIES.
The main 3D scanner categories:
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CMMs (coordinate measuring machines) and measuring
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probe heads. It is also possible to mount a 3D scanning head
on a CMM.
POSITIONING METHOD: MECHANICAL ENCODERS
CMMs with portable arms are positioned using the
mechanical encoders integrated in the arm.
Advantages
Limitations
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Optical tracking devices can track various types of measurement
tools, including the positioning of a 3D scanner.
POSITIONING METHOD: EXTERNAL OPTICAL TRACKING
DEVICE
These scanners use an external optical tracking device to establish positioning. They usually use markers (such as passive
or active targets) that optically bind the tracking device to the
scanner.
Advantages
Limitations
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These scanners project a pattern of light onto a part and process
how the pattern is distorted when light hits the object. Either an
LCD projector or a scanned or diffracted laser beam projects the
light pattern. One or two (sometimes more) sensors record the
projected pattern.
POSITIONING METHOD: OFFLINE TARGET POSITIONING AND
GEOMETRY POSITIONING
The scanner can either rely solely on the part geometry to position the data or rely on positioning targets (small stickers provided
with the system that can be placed directly on the part) to align 3D
data.
If only one camera is used, the position of the projector in relation
to the camera must be determined in advance; if two cameras are
used, the stereoscopic pair must be calibrated in advance.
Advantages
Limitations
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Many types of portable 3D scanners are available on the
market today, principally using laser-line or white-light
technologies.
Laser scanners project one or many laser lines on an object
while white-light devices project a light and shade pattern.
Both will analyze the resulting deformed projections to extract
the 3D data.
POSITIONING METHOD: REAL-TIME SELF-POSITIONING
THROUGH POSITIONING TARGETS, OBJECT’S NATURAL
FEATURES/TEXTURES OR HYBRID
Handheld scanners rely on two cameras to create what is
called stereoscopic vision. This enables the device to deWHUPLQHWKHVFDQQHUSRVLWLRQLQUHODWLRQWRVSHFLÀFSRLQWV
which could be positioning targets, the object’s natural
features or textures. Some newer portable scanners use a
mix of positioning types called hybrid positioning.
Advantages
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Limitations
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3D scanning has emerged as a critical tool in every
step of the product lifecycle management (PLM)
process. This is especially true of the new generation
of truly portable, self-positioning scanners.
The ability of 3D scanning to bridge the gap between
physical objects in the real world and the digital design environment has become extremely valuable in
a wide range of industries that use PLM -- aerospace,
automotive, consumer products, manufacturing, and
heavy industries among the principal ones.
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improved quality, reduced warehousing costs, and
better understanding of product performance.
In the pages that follow, we’ll explore
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different stages of PLM:
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3D scanning is used in the concept stage of PLM for a wide variety of processes, including determining
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Concept design
Concept prototyping
Concept
– Competitive product analysis
– Clay model measurement/Reverse
engineering
– Measurement of product environment
or connecting/Surrounding parts
– Models and mock-ups
measurement/Reverse engineering
– Measurement of existing parts for
aftermarket or custom equipment
– Styling and aesthetics
– Integration of prototype
PRGLÀFDWLRQVLQWR&$'ÀOH
– Form study, proof-of-concept
prototypes
– Ergonomy prototypes
“ Our research units include nearly 2,000 researchervs with experimental facilities.”
“ The detailed 3D scans and 3D
D model
allow us to accurately design and
integrate our sideboom attachment
chment
h
onto
the existing platform
form (tractor),””
says the vice president
resident of engineering
for Midwestern.
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accurate considerably
onsiderably minimizes the
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make to the platform. It also allows us
to
o completely visualize the design
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Midwest
Midwestern
Manufacturing produces sideboom
pipelayer attach
attachments for new and old tractors from
industry leaders such
suc as Caterpillar, John Deere, Case
and Komatsu. When
Whe 3D models are not available,
Midwestern uses reve
reverse engineering to capture a
tractor and create a ffully integrated sideboom.
oom.
The ability to quickly create a detailed,, accurate
model of the tractor jump-starts th
sign process
the design
and enables Midwestern to reduce product
dev
develo
elopment time.
development
3D scanning is used in the design stage of PLM for computer-aided design (CAD); rapid prototyping; and testing, simulation and analysis (CFD, FEA).
CAD design
Prototyping
Testing, simulation and analysis
Design
– 'VFDQWR&$'
– Reverse engineering
(extracting design-intent)
– Packaging design
– Rapid prototyping/Manufacturing
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– ,QWHJUDWLRQRISURWRW\SHPRGLÀFDWLRQV – Interference analysis
LQWR&$'ÀOH
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– Prototype inspection
“ Our research units include nearly 2,000 researchervs with experimental facilities.”
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manufacturer of customized parts and vehicles that
specializes in styling, engineering, CAD, FEA, manufacturing, CNC machining, binding and welding.
“ Considering how often we use our 3D
scanner, and if we add up the work
hours that we are saving, we expect to
get an excellent ROI very quickly.”
A motorcycle chassis is very complex and features
irregular shapes; as a result, the conventional methods
irregu
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tedious. Having no access to manufacturers’ 3D
tedi
powerful reverse engineering solution was
drawings, a p
needed to reduce the production times of CAD drawings.
- According to the president of Zeel Design
3D scanning makes
make it possible to easily and rapidly
obtain a highly accurate 3D
3 images of the assembly and
components at the same time—without
all of the existing component
having to draw them in 3D. The engineering
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drawings and the reverse
they previously spent on CAD drawi
self-positioning handengineering process. The use of a self-p
played a key role
held laser scanner right in the shop pla
ole
reduce design
in Zeel Design being able to drastically red
esign
project turnaround
turnaround times.
3D scanning is used in the manufacturing stage of PLM for applications such as tooling design, assembly and
production, and quality control.
Tooling design
Manufacturing
– Reverse engineering of dies, molds,
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tooling measurements
– Tooling validation/Inspection
Assembly/Production
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Quality control
– )
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– Supplier quality inspection
“ Our research units include nearly 2,000 researchervs with experimental facilities.”
The European Aeronautic Defense and Space (EADS)
company, recently renamed Airbus Group, performs 3D
optical scans of tooling equipment to assess the posVLEOHJHRPHWULFGLVWRUWLRQRIFDUERQÀEHUFRPSRVLWH
(carbon/epoxy) parts as well as post-manufacturing
deformation with parts/CAD comparisons.
First, EADS scans the tooling, in order to verify its
compliance with the CAD plan. Then, parts manufactured with this tooling are scanned, and the scanning
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The second
seco step consists of using very powerful simulation too
tools to estimate the distortion of the parts beIRUHPDQXID
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of the manufacturing parts.
The versatility of a portable 3D scanner made it the
tool of choice for this ta
task, both in its capacity to scan
h
unorthodox shapes, handle
hard-to-scan materials,
tly
such as composite parts, and perform scans directly
on the project’s site.
“ Thanks to its quick set up and
acquisition, ease of use, measurement
performance for many types of surface
states, and portability, the system
enabled us to quickly scan the metallic
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parts. The equipment’s portability made
it possible for us to record the
measurements right at the
manufacturing site.”
A member of the EADS Structure Health
Engineering (NDT & SHM) Department
“ Our research units include nearly 2,000 researchervs with experimental facilities.”
When it comes to manufacturing using molds and
dies, what you get is not always what you created in
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Stamping, casting and plastic injection are all
susceptible to phenomena such as shrinkage and
spring-back, which is the difference in shape between
the actual contours of dies and the shape of the
stamping produced in them. As a result, it is complicated to match the actual die or mold to the CAD
geometry.
wher portable 3D scanning comes in: 3D scan
That’s where
provide insights into deviations that might ocdata provides
m
cur during mold
and die production. The ability to
moni die and mold geometry and the
accurately monitor
corresponding parts it produces helps reduce design
iterations, saving time an
and resulting in parts that more
e.
accurately match the CAD reference.
3D scanning is used in the servicing stage of PLM for applications such as documentation; maintenance,
repair and overhaul (MRO); and replacement, recycling and restoration of parts.
Documentation
Maintenance, repair and
overhaul (MRO)
Servicing
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– Wear and tear analysis
parts/Tooling
– &
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systems, serious gaming
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Replacement/Recycling
– Reverse engineering for developing
replacement/Restoration parts
– 3ODQQLQJRIFRPSOH[DVVHPEOLHV
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“ Our research units include nearly 2,000 researchervs with experimental facilities.”
Atlas Weyhausen, a manufacturer of wheel loaders
and other heavy equipment, uses a portable 3D scanner to measure components and equipment for quality
assurance and for data feedback from prototype parts.
The company saves time and money from the increasing number of situations where components must
be inspected at their installed location or recorded
abroad at the supplier’s location.
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time for quality comparisons.
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easy
asy to see,””
says an Atlas quality assurance
surance manager.
“ Freeform surfaces are easy to align,
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the data feedback into our CAD system.””
3D scanning is used in digital reconstruction to capture
an actual object or environment -- such as an historical
artifact or a legacy product -- and reproduce it as accurately as possible for digital archiving, re-creation or
preservation.
3D scanning is used in customized manufacturing to
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existing consumer products, including toys, accessories
and apparel.
Custo
Customization extends to capturing the human body
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design.
A full range of app
applications can be found in the
Creaform website.
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“ Our research units include nearly 2,000 researchervs with experimental facilities.”
Milwaukee School of Engineering’s (MSOE) Rapid
Prototyping (RP) Center modeled a time capsule from
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jug. The time capsule was a central part of Face Jugs:
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exhibition that originated at the
Milwaukee Museum of Art.
The original face jug -- about the size of a grapefruit
-- wou
would normally be covered in a powder to reduce the
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done with a fragile, valuable piece.
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containing target d
dots that served as reference points
for the 3D scanner. Geomagic software was used to
upsize the scan model and create the compartments
and other fe
features of the time capsule.
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ating.
electroplating.
This e-book provided you with a high-level overview of
3D scanning and a glimpse into the multitude of new
possibilities and applications it enables in a variety of
disciplines.
Most of the key developments in 3D scanning have
come about in less than a decade. Indeed,3D scanning
is a fast-growing discipline with tremendous potential in
the future.
To explore a broader range of 3D scanning topics, we
invite you to visit the applications section on
www.creaform3d.com
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