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• Point Cloud Data for Inspection:
  If the data is to be used for inspection, the scanned object can be compared to the designer’s CAD nominal data. The result of this comparison process is delivered in the form of a “color map deviation report,” in PDF format, which pictorially describes the differences between the scan data and the CAD data.
• CAD Model for Reverse Engineering
  Laser scanning is the fastest, most accurate, and automated way to acquire 3D digital data for reverse engineering. Again, using specialized software, the point cloud data is used to create a 3D CAD model of the part’s geometry. The CAD model enables the precise reproduction of the scanned object, or the object can be modified in the CAD model to correct imperfections. Laser Design can provide a surface model or the more complex solid model, whichever results are needed for the application.

3D Scanning is done by either light-based technique (Structured Light Scanning) or by Laser.

Structured Light Scanning

Structured Light Scanning is the technique of capturing geometry via non-contact imaging. Structured light scanners use cameras to capture the behavior of fringe patterns projected on an object via a projector. The source of light, i.e. the projector technology, determines the type of scanner, whether Blue Light (usually LED Technology) or White Light (LED or DLP technology). Structured light technology is good where the quality and resolution of Data is very critical. These are flexible machines that can be calibrated for speed and resolution depending on the application. Being flexible, with these machines there is no limit to the size of the component which can be scanned. Structured Light Scanners produce data accuracy anywhere between +/-0.010mm – +/-0.080mm depending on scanned object size and calibration results. However, these accuracy values are manufacturer’s claims and not backed by any third party inspection bodies. Although this method is very lengthy for scanning and usually requires spraying the parts it is more suitable for reverse engineering where the resolution and depth of data are more important than accuracy.

Laser Scanning

laser scanning is the technique of capturing geometry via a non-contact method by running a 2D Laser via an LLP (Laser Line Probe) over an object. The LLP is mounted on a 7-Axis Arm, which controls the movement and position of the Scanner. Laser scanning is beneficial where the object cannot be sprayed in white color spray and no markers are required. However, the size of the component which can be scanned is dependent on the size of the Arm on which the LLP is mounted. This technology comes with certified accuracy delivering anywhere between +/-0.008mm – +/-0.075mm. Since this technology requires no part preparation before scanning (hence non-destructive method) and has certified accuracy, it is more suited towards Quality Inspection jobs. 

3D Scanning Glossary

Common 3D Scanning Industry Terms:

Many of our customers are new to 3D scanning or 3D laser scanning or are simply curious! We’ve compiled a glossary of common industry terms to help you learn more about the unique terms and phrases we use to describe the services, products, and valuable tools and techniques associated with 3D scanning.

• 2D Drawing– A 2D representation of a CAD model typically complete with measurements and dimensions for use in many manufacturing processes.
• 3D Modeling– 3D modeling refers to the creation of three-dimensional objects that are defined mathematically and geometrically (i.e. a circle extruded to a certain value to create a cylinder defined by its location, radius, and length). 3D modeling can be aided by the use of scan data (see Reverse Engineering).
• 3D Scanner– 3D scanners come in many forms, but the purpose of every one of them is to capture the shape, and sometimes color, of real-world physical objects or environments. This captured data is typically stored as a list of XYZ-coordinates in a point cloud file. 3D scanners can be categorized as contact (CMM arms) or non-contact (white light, 3D laser scanners, or stereo-vision based). Some can even capture internal features. “3D scanner” is sometimes misspelled as “3D scanner”.
• Accuracy– The accuracy is the closeness of a measurement to the actual feature. The opposite of accuracy is uncertainty, which is an inverse perspective of the same value. See Uncertainty.
• CAD– Computer-Aided Design. CAD is a standard term defining a group of software that aides in design. CAD software is what is used for 3D modeling and to create 2D drawings. It is typically used in manufacturing or other engineering disciplines. For example An engineer designs in SolidWorks, Pro-E, AutoCAD, CATIA, or Unigraphics; all of which are CAD or CAE programs. Often confused with CAE.
• Class A– The most simple mathematical curve or surface that can describe a shape. Example: A customer requests a “Class A” IGES surface when he needs a super smooth surface typically used in aerospace or automotive applications.
• Color Map– A color plot visually representing deviations from actual to theoretical.Example: A customer requests a colormap inspection when needing to compare an as-built object to its-designed CAD data.
• Degrees of Freedom– Describes the numbers of directions of movement and refers to how the position and orientation of an object are described relative to a coordinate system. In 3D scanning it usually consists of three linear translations (X, Y, and Z) and three rotations about the three axes (pitch, yaw, and roll).
• Deviation– As typically applied to 3D scanning, deviation refers to the difference
  in the size and shape of a manufactured part versus its design specifications. The deviation is easily discovered by quality inspection with the use of color maps and cross-sectional analysis found in CAI applications.
• Digital Archiving– Storing data digitally. Objects can be scanned and processed for digital archiving purposes, reducing the need to store physical parts in locations such as a warehouse.
• Geometric Dimensioning & Tolerancing (GD&T)– Geometric Dimensioning and Tolerancing is a standard used to define the nominal geometry of parts and assemblies, to define the allowable variation in form and possibly size of individual features, and to define the allowable variation between features.
• IGES– Initial Graphics Exchange Specification / System is a standard mathematical surface file, used for over 25 years in most CAD systems to mathematically represent physical data. It is the most common format for exchanging CAD data between software programs.
• Legacy Part– A part that is already created or existent in the customer environment. As typically applied to 3D scanning, legacy parts usually do not have CAD data.
• Organized STL– Mesh data consisting of point cloud data with mathematical point spacing based on surface data. An organized STL of a cube would consist of 8 points (1 for each corner).
• Parametric Model– A data set that retains the history of how it was designed, so that modifications update all downstream features. The exchange of such models is supported by IGES. SolidWorks is a software program that is popular for creating and modifying parametric models.
• Point Cloud– A point cloud is the computer visualization of the XYZ coordinates that describe a physical object or environment. Each point represents an actual point on the object or in the environment, and collectively describes its shape and measurements. Points can be captured individually, such as with a CMM, or thousands at a time, such as with a 3D laser scanner that captures multiple points sets from different perspectives that can be merged into a cloud. Point clouds are typically represented by an unorganized STL file. Synonymous with raw scan data
• Quality Inspection– The process of evaluating a physical part and comparing it to the design specifications that are described in the object’s CAD file. Inspection is an “as-built” vs “as designed” comparison. See also Deviation.
• Reverse Engineering– Reverse engineering broadly refers to analyzing and dissecting something to recreate it. In 3D scanning, reverse engineering typically means the process of measuring an object using a 3D scanner and then creating CAD data that reflects its original design intent. This can also be done by using rulers, calipers, or a CMM. Reverse engineering is sometimes referred to as Reverse Modeling.
• Scan– Measuring the part, capturing data, and transferring the measured points to the computer. It also refers to the computer file that is based on the physical part, i.e., XYZ coordinates that represent physical measurements taken by the scanner.
• STEP– Standard for the Exchange of Product Model Data is a comprehensive ISO data standard (ISO 10303) for the exchange of object descriptions between systems. STEP is a file format that is usually interchangeable with IGES.
• STL– Standard Tessellation Language. STL is a special internationally recognized file format that stores XYZ coordinate measurements and their normals. Gives the added functionality beyond XYZ coordinates
  enabling visualization of a part’s “front” and “back.” STL is the standard file format for rapid prototyping and is used in reverse engineering. See Organized STL and Unorganized STL.
• Talc– Talc powder is typically applied to translucent, reflective, or black/near-black objects during the 3D laser scanning process to improve the ability of the laser scanner to capture data. Talc powder is predominantly white and is usually applied with a pen or an aerosol spray. Talc can easily be wiped off and cleaned, and generally will not damage an object.
• Touch Probe– A Coordinate Measuring Machine (CMM) that requires physical contact with the part to measure it.
• White Light Scanning (Interferometry)– Optical non-contact method for measuring physical parts. White light scanners obtain measurements of an object by determining changes in the fringe and distortion of a pattern of white light projected on an object.

What is the ROI of 3D Scanning?                                                                                                                                                   

A mold maker wanted to re-qualify used molds to see if they needed refurbishing, and if so, where to make the corrections.

PREVIOUS METHOD: Manual Hand Measurement

• Time: 10 weeks to complete one part + production time
• Cost: Approximately 200 hours at $50/hour = $10,000
• Method: Gages and instruments are used to manually measure the mold’s dimensions and locations. The measurements are compared to the 2D drawing and a report of discrepant items is generated. Then, engineers decide which of the discrepant items were due to processing of the mold and which had to be corrected in the tooling.

NEW METHOD: High-Speed 3D Scanning

• Time: 2 hours to scan each part + time for generating inspection reports = 30 hours (3-4 days)
• Cost: Scanning each mold, plus detailed iterative inspection and reporting process to final documentation = Less than half the cost of the Manual Method
• Method: 3D scanning expedites parts’ production exponentially. A color-coded inspection report (or point cloud data for CAD modeling) is quickly generated that provides more information about the part’s acceptability.

How Else Did the Company Benefit from 3D Scanning?
Based on the scan data, the mold maker could quickly be certain that the newly refurbished mold met the criteria of the 2-D drawing and the acceptable standards. The digital scan data also allowed the mold maker to correct the CAD model so that it matched all the dimensions of the drawing. Future inspections will be fast and efficient because the scanning setup is saved as a template so when the same part is inspected, it is immediately available. Molds can be qualified in just hours and at regular intervals by laser scanning inspection techniques. Not only did the customer save time with 3-D scanning, but they also saved over half the cost of manual measurement.

Choosing the Right Laser Scanning Inspection Technique
Two main factors should be considered when scanning molds: size and accuracy.

1. Size consideration:

• If you need profile data of your small to medium-sized part, laser scanning on a fixed system with a high-accuracy probe yields the best results.
• If you need profile data of large parts or onsite scanning, a portable arm-based laser probe suits your needs.
• For internal cavity scanning on parts that cannot be damaged, CT scanning provides complete detailed external and internal data.

2. Accuracy consideration:

• A service bureau should be able to provide cost-effective scanning options depending on the size and accuracy requirements of the job—using the highest accuracy system and a probe is not always necessary. Lower accuracy scanning probes reduce the scan time while providing adequate and reliable data economically.

A large section of Industries using 3D Scanning for a different purpose:

• Aerospace
• Architecture, Engineering, Construction
• Automotive
• Forensics
• Foundry
• Heavy Machinery
• Hydro Power
• Law Enforcement
• Machine Shop
• Medical

There are many 3D Scanning application some of these are:

• 2D to 3D CAD conversions
• As-built Documentation
• Body Scanning application
• CAD Based inspection
• CGI and visual effects
• FEA- Finite Element Analysis
• Gear Inspection
• In-process inspection
• Dimensional Analysis
• Emergency response scanning

MaXellence Engineering Technologies believes in providing an excellent variety of 3D Scanning Solutions to our clients.