When documenting object geometry information, laser scanning is an effective solution. Let’s consider how the technology works, what are the advantages and what prospects are already available for improvements.

What is reverse engineering?

Reverse engineering is a study of the finished object, its documentation and working principles for further improvement and modernization. Using technology, you can find undocumented features, change or create a device with similar functions, while avoiding direct copying.

The main task is to find new solutions for finished products based on data analysis.

Simply put, the technology allows you to analyze information about the finished sample and understand how modernization is possible and appropriate. From the point of view of new technologies, the assessment of input data, materials, requirements of the buyer and/or manufacturer is carried out.

For example, there is a car that was released 50 years ago. Instead of a complete reconstruction of the machine, you can perform a partial one: replace individual units using new materials. It is important to make sure that the new part matches the old design. During the study of the object, engineers discover incomplete/inaccurate geometry data or their absence. Laser scanning will help to collect all the necessary information and restore the car.

Laser scanning — the ability to combine virtual and physical spaces. One application of the technology is to recreate parts that are no longer manufactured.

Thanks to ultra-precision, which has no analogs, laser scanning is indispensable in such demanding areas as turbine engineering or the space industry.

The equipment allows you to create a digital copy with an accuracy of 8 microns (for comparison: the thickness of a human hair is 70 microns). But this is not possible for all objects. For example, the height of the Eiffel Tower, assembled from metal structures, fluctuates within 8 centimeters at different times of the year. It is necessary to take into account the error that occurs under the influence of temperatures.

World practice

An interesting case is with Siemens. Using reverse engineering, the industrial giant managed to restore the steering gear of a centenary automobile without access to the original technical drawings. Ruston Hornsby details were scanned and a new mechanism was recreated in just five days.

Founded by Siemens conglomerate, Materials Solutions is engaged in the development of parts in many areas, including the aerospace industry.

As Phil Hatherley, general manager of the company, noted, reverse engineering is digitalization that you can touch. The technology has no boundaries: it allows you to work with materials, geometry, and spaces of any complexity.

Picture Credit: Pexels

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For pre production

When you are considering printing technology together with 3D scanning in pre production, you need t be sure of the quality of the device and its level of performance. Pre production includes the manufacturing which takes place prior to a product’s large scale orders. Thus, if you are desirous of doing a just a little run, it could be really expensive performing the task without the use of traditional methods. However, when have already invested in 3D scanner and printer, printing becomes and easier process. When you think of bringing about some physical changes, you require scanning the components. You can thus create new models in just a few days, than weeks that would otherwise go in sending the items back for manufacturing. The time between phase of pre production and launch of the product is thus reduced.

Digital Geometric Design

Traditional manufacturing is not always appropriate in the case of some designs. This is the only reason why value is placed with digital 3D scanning and 3D printing technologies. You can also create such designs on computer that do not have to be geometrically limited. Objects become more intricate and complex than when they are produced in large numbers or in masses. Moreover, making the objects does not require the hand to labour. These possibilities give issuance to the items which are more functional and more detailed. One additional benefit is that less quantity of waste is produced. As it is that the material is laid down just in the way it is used, the quantity of waste production is reduced to a great extent. Money is thus saved on materials, on labour, and practically, from the vantage point of manufacturing.

The digital design applications include jewellery, medical instruments, dental devices, and lot more. In our next session, we would continue with the discussion of the aspects of the technology of 3D scanning. The process, though appears a little complicated in the beginning, is actually quite straightforward.

Author: Tony Rolland provides marketing service for EMS USA (http://www.ems-usa.com/), Florida based company offers 3D printing and 3D scanning services and also product development products such as 3D Systems, 3D Printers and 3D Scanners.

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3D scanning study of this kind has never taken place before and it was only during the mid-80’s offshore workers body size survey was conducted. The most interesting thing to notice is that since then, workforce weight has risen by almost 19%.

The research aims to gather as much data as possible so that daily work and even emergency situations do not falter because of improper safety issues. During evacuation procedures, it is always better to have an idea regarding space availability inside helicopters and lifeboats. This helps in evacuating people easily and mishaps can be easily avoided.

Two scanners will be used by researchers for production of 3D image. These processes can be easily completed within a matter of few seconds. The devices used are portable and assists researchers in collecting data easily from different locations.

The research has received a funding of £ 150,000 and some of the well known researchers from all over the world are leading this project. The 3D scanning study is anticipated to bring about huge changes that will offer workers with more safety than what was available a few years earlier.

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Steinbichler has revised the model of its 3D scanner. It offers a completey new and modified 3D scanning service with the Comet L3D scanner that has a capacity of 5MP. The resolution has been improved in the newer version so as to enable a better capturing of surface details of objects.

The scanner is both efficient and compact and it opens before you a completely new dimension in the acquisition of 3D data with the help of the new LED technology. The precision involved in data capturing by this portable device accomplishes the task quicker and more efficiently. Being economic, the scanner also offers great solution for the entry level users. The construction of the device is robust and the components are dust proof so that it may be used in industrial conditions. Moreover, the sensor can be positioned with the help of the tripod.

The technology of BLUE-LED offered by the 3D scanning service enables quick recording up to five million points for measuring. Where the object has quite of lot of minute features and details, this device works more efficiently and faster. Low distance enables a trouble free work in places that are confined.  The concept of the software offers a combination with the photogrammetric procedures for measuring so as to digitalize the large objects.

The area of functioning of the sensor is diversified. It was launched in mid 2011, and since then, has played an important role in 3D scanning.

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Systems for 3D scanning find use in various industries like aerospace, automotive, manufacturers and medical. Digital information is captured about an object shape by using equipment using light or laser to measure distance between object and scanner. Small size objects can be easily captured along with full-size skyscraper buildings or aeroplanes.

Real time data is digitized by these equipments which are then incorporated into CAD systems. Unlike handheld devices, conventional scanning equipments require different setups and one need to aim target surfaces directly. 3D scanners that are handheld can easily capture data of large surfaces like boat hulls for creating digital models.

Per second multiple points can be captured by laser 3D scanners with the help of their advanced technology and functionalities. Inspection of production parts happens quite fast with such type of scanners. The 3D scanning methodology helps to provide better quality, good fitting parts as well as reduction in cost. The accuracy percentage differs from equipment to equipment. Different manufacturers use different technology and mechanism to build their products.

Physical measurements are quickly captured for all physical objects. Another significant benefit is that time consumed in the design work can be lessened to a great extent. Manual procedures require huge time and the outcome of the task is often not satisfactory. However, such occurrences rarely happen with 3D scanning as the design of the material is highly enhanced. Costs for sheet metal formation and metal fabrication are reduced to a large extent.

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Re-creation of Blackhawk helicopter maintenance entry area was required to be performed. But, the only problem was that the interior and the doors were quite complicated and CAD models were not available to work on. The 3D scanning services from EMS helped to complete the entire task.

The complicated structure of the area was extremely difficult to access and the Z800 scanner was put to use by EMS for collecting all the data required for building a CAD model. As there is no tripod or arm attached with the scanner, it made the task extremely easy by getting into the crannies and nooks. A proper scanned image was taken from the helicopter’s top by EMS. The helicopter’s upper portion was captured within two hours or so along with every mechanical part under the entry doors.

After the completion of the scan, raw data was turned to CAD model. This procedure was carried out with the help of the 3D scanning RapidForm software. It is possible for engineers to import data by using the software and create 3D model and surface. After the completion of the procedure, the entire data was given to the supplier that would assist future technicians with repairing Blackhawk helicopter. Through manual measurements it would have been an extremely difficult task to build some model accurately.

Complicated shapes can be replicated exactly for modeling by using 3D scanning. The service offered by EMS was not only outstanding but transformed a complicated machinery piece within a few hours which would have been impossible with any other procedures. The inception of such technologies not only promises a brighter future but ensures that every work is done with perfection and accuracy. This is mainly the reason why an increasing number of companies are adopting such technologies to increase the efficiency of their business and reach new heights of success.

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