An Introduction to 3D Scanning E-Book

. Focused on rapid product development products & services . 3D Scanning, 3D Printing, Product Development . Founded in 2001 . Offices in Tampa, Detroit, Atlanta . 25+ years of Design, Engineering & Mfg Experience . Unmatched knowledge, service & support . Engineers helping engineers . Continuous growth every year . Major expansion in 2014 . More space . More equipment . More engineers . Offices Tampa, Atlanta, Detroit

2 © 2011 Engineering & Manufacturing Services, Inc. All rights reserved. While the mainstream media continues its obsession with 3D printing, another quiet, perhaps more impactful, disruption is revolutionizing the way products are designed, engineered, manu- factured, 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.

Portable 3D scanning is fueling the movement ACCORDING TO A RECENT STUDY from the laboratory to the front lines of the BY MARKETSANDMARKETS, THE factory and field, driven by the following key 3D SCANNING MARKET WILL GROW factors: NEARLY &RQYHQLHQFHDQGIOH[LELOLW\IRUDZLGHYDULHW\RIDSSOLFDWLRQV LQFOXGLQJHYHU\DVSHFWRISURGXFWOLIHF\FOHPDQDJHPHQW PLM)

15% 6LPSOLFLW\DQGDXWRPDWLRQWKDWVSUHDGVXVHEH\RQG ANNUALLY OVER THE NEXT FIVE VSHFLDOLVWVLQWRPDLQVWUHDPHQJLQHHULQJ YEARS, WITH THE PORTABLE 3D SCANNING SEGMENT /RZHUFRVWVWKDWEURDGHQWKHPDUNHW LEADING THE WAY. *UHDWHUDFFXUDF\VSHHGDQGUHOLDELOLW\IRUPLVVLRQFULWLFDO SURMHFWV 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 ([WUDFWLQJGLPHQVLRQVWRUHFRQVWUXFWDCADUHIHUHQFHILOHIRU SCANNED IN 3D FOR UHYHUVHHQJLQHHULQJRUUDSLGSURWRW\SLQJ

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Reverse engineering

GEOMETRICAL ENTITIES

MESH

CAD

3D COMPARISON PART SCAN

2D COMPARISON

Inspection There are TWO major categories of scanners based on the way they capture data:

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7DNHVLQJOHVQDSVKRWVRUVFDQV &DSWXUHPXOWLSOHLPDJHVFRQWLQXRXVO\ 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 &RPSXWHUVRIWZDUHFDQEHXVHGWRFOHDQXSWKHVFDQGDWDÀOOLQJKROHVFRUUHFWLQJHUURUVDQGLPSURYLQJGDWDTXDOLW\ 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: 0HDVXULQJDUPVSRUWDEOH&00VFDQQHUV 7UDFNHG'VFDQQHUV 6WUXFWXUHGOLJKW'VFDQQHUV 3RUWDEOH'VFDQQHUV CMMs (coordinate measuring machines) and measuring DUPVFDQEHHTXLSSHGZLWKHLWKHUÀ[HGSUREHRUWRXFKWULJJHU 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

0DQ\GLIIHUHQWWRROVFDQEHPRXQWHGRQSRUWDEOH&00VPDN 3RUWDEOH&00VQHHGWREHIL[HGRQDVXUIDFHDQGXVHDSK\VL LQJLWSRVVLEOHWRHDVLO\LQWHJUDWHVFDQQLQJDQGSURELQJLQWKH FDOOLQN DUP DVWKHLUSRVLWLRQLQJPHWKRG7KLVPDNHVWKHP VDPHSURMHFW SURQHWRYLEUDWLRQVDQGRWKHUHQYLURQPHQWDOFRQVWUDLQWVWKDW FDQDIIHFWWKHSHUIRUPDQFHDQGTXDOLW\RIWKHUHVXOW7KH\DOVR ODFNIOH[LELOLW\LQWHUPVRIWKHORFDWLRQVLQZKLFKWKH\FDQEH XVHGDQGWKHVKDSHRIWKHREMHFWVWKH\FDQVFDQ 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 es- tablish 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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hese 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 +LJKHQGVWUXFWXUHGOLJKWVFDQQHUVJHQHUDWHYHU\KLJKTXDOLW\ :KLOHZKLWHOLJKWVFDQQHUVFDQDFTXLUHODUJHTXDQWLWLHVRIGDWD GDWD7KH\W\SLFDOO\GHOLYHUH[FHOOHQWUHVROXWLRQZKLFKDOORZV LQRQHVFDQRYHUDOOSURMHFWVSHHGLVQRWDOZD\VLPSURYHGE\ IRUWKHVPDOOHVWIHDWXUHVRQDQREMHFWWREHFDSWXUHGLQWKH WKLVPHWKRGRORJ\0XOWLSOHVFDQVDUHUHTXLUHGLQPRVWFDVHV UHVXOWV WRFRYHUDOODQJOHVRQPRUHFRPSOH[SDUWVZKLFKLVYHU\WLPH FRQVXPLQJ 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 Advantages while white-light devices project a light and shade pattern. Both will analyze the resulting deformed projections to extract 3RUWDEOH'VFDQQHUVFDQEHWUDQVSRUWHGZLWKPLQLPXPHIIRUW the 3D data. DQGDUHRIWHQHDVLHUWRXVHWKDQRWKHUVFDQQHUW\SHV7KH\ FDQFRPELQHPXOWLSOHSRVLWLRQLQJPHWKRGVSURYLGLQJWKH DFFXUDF\RISRVLWLRQLQJWDUJHWVZLWKWKHIOH[LELOLW\RIREMHFW POSITIONING METHOD: REAL-TIME SELF-POSITIONING IHDWXUHVDQGWH[WXUHSRVLWLRQLQJ7KHPRVWDGYDQFHGWHFKQROR THROUGH POSITIONING TARGETS, OBJECT’S NATURAL JLHVFDQDFTXLUHPRUHWKDQKDOIDPLOOLRQSRLQWVSHUVHFRQG FEATURES/TEXTURES OR HYBRID DQGUHEXLOGWKH'WULDQJOHPHVKOLYHGXULQJWKHVFDQQLQJ Handheld scanners rely on two cameras to create what is SURFHVV called stereoscopic vision. This enables the device to de- WHUPLQHWKHVFDQQHUSRVLWLRQLQUHODWLRQWRVSHFLÀFSRLQWV which could be positioning targets, the object’s natural Limitations features or textures. Some newer portable scanners use a mix of positioning types called hybrid positioning. 3RUWDEOHVFDQQHUVXVHVHOISRVLWLRQLQJRQDPRUHORFDODUHD ZKLFKPHDQVWKDWHUURUVFDQVWDFNXSDVWKHVFDQQLQJYROXPH JURZV,WLVSRVVLEOHWRFLUFXPYHQWWKLVE\XVLQJWHFKQRORJLHV VXFKDVSKRWRJUDPPHWU\DQGSRVLWLRQLQJWDUJHWVWRPLQLPL]H HUURUVEXWWKHVHDGGLWLRQDOVWHSVPLJKWLQFUHDVHVHWXSWLPH DQGOLPLWWKHVL]HRIWKHREMHFWVRUDUHDVWKDWFDQEHVFDQQHG HIILFLHQWO\ 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.

7KHVHLQGXVWULHVEHQHÀWIURPIDVWHUWLPHWRPDUNHW improved quality, reduced warehousing costs, and better understanding of product performance.

&RQFHSW In the pages that follow, we’ll explore 'HVLJQ WKHEHQHÀWVRI'VFDQQLQJLQIRXU 0DQXIDFWXULQJ different stages of PLM: 6HUYLFLQJ 3D scanning is used in the concept stage of PLM for a wide variety of processes, including determining UHTXLUHPHQWVDQGVSHFLÀFDWLRQVFRQFHSWGHVLJQ LQFOXGLQJUHYHUVHHQJLQHHULQJ DQGFRQFHSWSURWRW\SLQJ

5HTXLUHPHQWVDQGVSHFLÀFDWLRQV Concept design Concept prototyping Concept

– Competitive product analysis – Clay model measurement/Reverse – Integration of prototype – Measurement of product environment engineering PRGLÀFDWLRQVLQWR&$'ÀOH or connecting/Surrounding parts – Models and mock-ups – Form study, proof-of-concept – Measurement of existing parts for measurement/Reverse engineering prototypes aftermarket or custom equipment – Styling and aesthetics – Ergonomy prototypes “ Our research units include nearly 2,000 researchervs with experimental facilities.”

“ The detailed 3D scans and 3DD model allow us to accurately design and integrate our sideboom attachmentchmenth onto the existing platformform (tractor),” says the vice presidentresident of engineering for Midwestern. “ 7KHIDFWWKDWWKH VFDQ ÀDWWKH VFDQ ÀOHVDUHVR accurate considerablyonsiderably minimizes the DPRXQWRIPRGLÀRIPRGLÀFDWLRQVZHKDYHWR make to the platform. It also allows us too completely visualize the design EHIRUHÀIRUHÀQDODSSURYDODQGSURGXFWLRQ” MidwesternMidwest Manufacturing produces sideboom pipelayer attachattachments for new and old tractors from industry leaders suchsuc as Caterpillar, John Deere, Case and Komatsu. WhenWhe 3D models are not available, Midwestern uses revereverse 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 ththe designsign process and enables Midwestern to reduce product developmentdevdeveloelopment time. 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&$' – Rapid prototyping/Manufacturing – )LQLWHHOHPHQWDQDO\VLV )($ – Reverse engineering – ,QWHJUDWLRQRISURWRW\SHPRGLÀFDWLRQV – Interference analysis (extracting design-intent) LQWR&$'ÀOH – 'HIRUPDWLRQJHRPHWU\DQDO\VLV – Packaging design – Prototype inspection “ Our research units include nearly 2,000 researchervs with experimental facilities.”

=HHO'HVLJQLVDQHQJLQHHULQJFRQVXOWLQJÀUPDQG “ Considering how often we use our 3D manufacturer of customized parts and vehicles that scanner, and if we add up the work specializes in styling, engineering, CAD, FEA, manufac- hours that we are saving, we expect to turing, CNC machining, binding and welding. get an excellent ROI very quickly.” A motorcycle chassis is very complex and features - According to the president of Zeel Design irreguirregular shapes; as a result, the conventional methods XVHGIRXVHGIRUGHVLJQLQJPRGLÀHGFRPSRQHQWVDUHORQJDQG teditedious. Having no access to manufacturers’ 3D drawings, a ppowerful reverse engineering solution was needed to reduce the production times of CAD drawings.

3D scanning makesmake it possible to easily and rapidly obtain a highly accurate 3D3 images of the assembly and all of the existing componentcomponents at the same time—without having to draw them in 3D. The engineering FRQVXOWLQJÀUPPDQDJHGWRUHGXFHE\WKHWLPHUPPDQDJHGWRUHGX they previously spent on CAD drawidrawings and the reverse engineering process. The use of a self-pself-positioning handheld laser scanner right in the shop plaplayed a key roleole in Zeel Design being able to drastically redreduce designesign project turnaroundturnaround 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 Assembly/Production Quality control Manufacturing

– Reverse engineering of dies, molds, – 9LUWXDODVVHPEO\ – )LUVWDUWLFOHLQVSHFWLRQ )$, À[WXUHVMLJVDQGSDWWHUQV – 7RRO5RERWSDWKSURJUDPPLQJ – 3DUWWR&$'LQVSHFWLRQ – 8SGDWHRI&$'ÀOHWRUHÁHFWDVEXLOW – 3DUWDVVHVVPHQWEHIRUHPDFKLQLQJ – Supplier quality inspection tooling measurements – Tooling validation/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 pos- VLEOHJHRPHWULFGLVWRUWLRQRIFDUERQÀEHUFRPSRVLWH (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 manufac- tured with this tooling are scanned, and the scanning ÀOHVDUHFRPSDUHG “ Thanks to its quick set up and acquisition, ease of use, measurement The secondseco step consists of using very powerful simulation tootools to estimate the distortion of the parts be- performance for many types of surface IRUHPDQXIDIRUHPDQXIDFWXULQJLQRUGHUWRFRPSDUHWKHVFDQÀOHV states, and portability, the system of the manufacturing parts. enabled us to quickly scan the metallic WRROLQJDQGFDUERQÀEHUFRPSRVLWH The versatility of a portable 3D scanner made it the tool of choice for this tatask, both in its capacity to scan parts. The equipment’s portability made unorthodox shapes, handleh hard-to-scan materials, it possible for us to record the such as composite parts, and perform scans directlytly measurements right at the on the project’s site. 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 WKH&$'ÀOH

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 compli- cated to match the actual die or mold to the CAD geometry.

That’s wherewher portable 3D scanning comes in: 3D scan data providesprovide insights into deviations that might oc- cur during moldm and die production. The ability to accurately monitormoni die and mold geometry and the corresponding parts it produces helps reduce design iterations, saving time anand resulting in parts that more accurately match the CAD reference.e. 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.

Maintenance, repair and Documentation overhaul (MRO) Replacement/Recycling Servicing

– $VEXLOWGRFXPHQWDWLRQRI – Wear and tear analysis – Reverse engineering for developing parts/Tooling – &XVWRPUHSDLUV0RGLÀFDWLRQ replacement/Restoration parts – 0DUNHWLQJSUHVHQWDWLRQV'WUDLQLQJ – $VEXLOWGRFXPHQWDWLRQRI – 3ODQQLQJRIFRPSOH[DVVHPEOLHV systems, serious gaming SDUWV7RROLQJEHIRUHPDLQWHQDQFH GLVDVVHPEO\'LVPDQWOLQJ – 'LJLWDODUFKLYLQJ “ Our research units include nearly 2,000 researchervs with experimental facilities.”

Atlas Weyhausen, a manufacturer of wheel loaders “ 7KHPDMRUEHQHÀWRIWKHVFDQQHULVFDQQHULV and other heavy equipment, uses a portable 3D scanner to measure components and equipment for quality easyasy to see,” assurance and for data feedback from prototype parts. says an Atlas quality assurancesurance manager. The company saves time and money from the increas- “ Freeform surfaces are easy to align, ing number of situations where components must be inspected at their installed location or recorded DORQJZLWK'GDWD$IXUWKHUEHQHÀ$IXUWKHUEHQHÀWLV abroad at the supplier’s location. the data feedback into our CAD system.”

+DYLQJGLJLWDOÀ+ OHVIRUDFRPSRQHQWLVDPDMRUEHQHÀW TheT steel construction of a new driver’s cab and vari- ouso paneling sections have been digitized, for ex- DPSOHDQGWKHUHVXOWLQJ&$'ÀDPSOHD OHVDUHDYDLODEOHDWDQ\ time for quality comparisons. 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 HQDEOHQHDUO\LQÀQLWHYDULDWLRQVRQEDVLFGHVLJQVRI existing consumer products, including toys, accessories and apparel.

CustomizationCusto extends to capturing the human body IRULQGLYLGXDOL]HGPHGLFDOGHYLFHVDQGIRUÀIRULQGLY WWRERG\ design.design.

A full range of appapplications can be found in the Creaform websitewebsite.. 2LODQG*DV2LODQG*DV +HDOWK&DUH (GXFDWLRQDQG5HVHDUFK(GXFDWLRQDQG5HVHDUFK &RPSXWHUJUDSKLFVVSHFLDOHIIHFWV&RPSXWHUJUDSKLFVVSHFLDOHIIHFSJSJ 'L 'LJLWDOSUHVHUYDWLRQJLWDOSUHVHUYDWLRQ $UWVDQGDUFKLWHFWXUH$UWVDQGDUFKLWHFWXUH 9LUWXDOUHDOLW\9LUWXDOUHDOLW\ “ 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 'VFDQGDWDRIDQDFWXDOWKFHQWXU\(GJHÀHOGIDFH jug. The time capsule was a central part of Face Jugs: $UWDQG5LWXDOLQWK&HQWXU\6RXWK&DUROLQDDQ exhibition that originated at the Milwaukee Museum of Art.

The original face jug -- about the size of a grapefruit -- wouwould normally be covered in a powder to reduce the UHÁHFWLYHFWLYLW\RIWKHFHUDPLFÀQLVKEXWWKDWFRXOGQRWEH done with a fragile, valuable piece.

062(FRY062(FRYHUHGWKHIDFHMXJZLWKDÀQHEODFNQHW containing target ddots that served as reference points for the 3D scanner. Geomagic software was used to upsize the scan model and create the compartments and other fefeatures of the time capsule.

7KHÀQDOSURGXFWZDV'SULQWHGDQGÀQDOSURGXFWZDV'SUL QLVKHGZLWKLWK electroplating.ating. 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 'VFDQQHU$GHYLFHWKDWFDSWXUHVGDWDRQWKHVKDSHDQGFRORUVRIDUHDOZRUOGHQYLURQPHQWIRUSURFHVVLQJLQWKHGLJLWDO ZRUOGVXFKDVFRQVWUXFWLRQRI'PRGHOV

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. Proven History . Success since 2001 . Quality . Our goal is to deliver the highest quality on time, every time . Experience . Working in industry since 1984 . Growth . Consistent growth based on repeat & referral business . 1000’s of projects – design, rapid prototyping, 3D scanning