APPLICATION REPORT stereoSCAN „Mansory Edition“ - exclusive tuning of premium class luxury cars Distinguished bodywork design combined with a stylish interior and enhanced engine performance at the highest level: This is the quality commitment mission of the famed German automobile tuning company Mansory. The high-precision measuring system stereoSCAN An experienced car tuning team develops and produces As part of the production process, these individual individually designed styling kits for the exterior and interior design features or add-on parts, among other mate- features of premium class automobiles. The various design rials made of carbon fiber or aluminum, have to be processes as well as the quality control procedures for the final captured three-dimensionally in order to conduct a touches of a Mercedes-Benz, Ferrari, Bentley, Lamborghini, or targeted quality analysis and — as the case may be Porsche require a flexible, fast and highly precise measuring — allow for relevant optimization measures prior to technique: this is when the three-dimensional data acquisition the creation of the production molds. with a breuckmann stereoSCAN is called into action. Measuring system and setup Objective and measuring object In light of the requested measuring accuracy of down to 0.1 millimeter over the complete vehicle length, The versatile customization of a strictly limited “Mansory Edition” along with the different surface properties of the series begins with the three-dimensional scan of the bodywork and measuring objects, Mansory uses the breuckmann interior of an already existing vehicle. The key objective is a time effi- 3D measuring system stereoSCAN with its easily cient, highly precise, contact free measurement of all relevant objects adjustable, flexible measuring fields. involved, varying from the smallest car detail measuring only a few centimeters, the complete car exterior, various types of edges as well Should the 30° triangulation angle not, or only with as car interior areas which are difficult to access. Some of the objects significant extra effort, be able to measure narrow feature shiny or glossy surfaces, making scanning without pretreat- structures due to the complexity of the object geo- ment with anti-reflective matting spray a further essential requirement. metry, the additional 20° and 10° triangulation angles The surface model, created from the high-precision 3D measuring of the stereoSCAN allow for a significant effort re- data generated in the scanning process, serves as a basis for the duction during the data capture process, making this subsequent design phase. The redesigned body kit attachments of the scanner the ideal tool to ensure the fastest possible customized “facelift” have to be integrated seamlessly into the existing object acquisition together with prime level data vehicle shape. quality and easy handling. Mansorys Aston Martin Vantage V8 Workflow After the Mansory tuning team has properly positioned the vehicle to be customized and calibrated the measuring system, the first step of measuring the outer shell of the vehicle is carried out with photo- grammetry. In the subsequent step, the three-dimensional surface area acquisition of the car is conducted using the large measuring field configuration of the stereoSCAN. After a quick change to a smaller measuring field, the subsequent areas to be measured are the interior as well as selected smaller feature details of the vehicle. AICON‘S in-house scanning and evaluation software OPTOCAT then 3D data of an engine block cover automatically collects the scan data in a consolidated coordinate sys- tem and after the data capture is fully completed, assembles the scan images into a coherent 3D surface model of the vehicle. Thanks to the high-precision scanning time of the stereoSCAN, Mansory performs car tuning at the highest level. The newly developed bodywork com- ponents are characterized by a perfectly accurate fit and integrate seamlessly into the existing body- work and interior of the vehicle. The average cus- tomized redesign takes between one and two years. The fast and flexible scanning process along with its prime quality data output contributes to significantly faster cycle times of the surface design progress and to a considerably more efficient production process. Jakob Jarusek, experienced designer at Mansory, and Mehdi Karimzadeh, Mansory scanning techni- cian, summarize the benefits in one sentence: „3D data acquisition with the stereoSCAN is the per- fect technical complement in the premium segment High precision 3D capturing of the vehicle`s exterior of car tuning.” Conclusion Contact / Link The design and tuning experts at Mansory use the high-precision 3D Mansory Design & Holding GmbH, measuring data of the vehicle’s exterior and interior as the starting 95682 Brand, Germany — www.mansory.com point to develop the new design of a vehicle. This scan data not only serves as a basis to generate exclusive customized car designs and to We would like to thank Mr. Jakob Jarusek and Mr. conduct targeted quality inspections for the optimization of the newly Mehdi Karimzadeh for their cooperation and support designed components, it is also used for the creation of any necessary in compiling this application report. new production molds and individual components. AICON 3D Systems GmbH Biberweg 30 C | D-38114 Braunschweig tel. +49 (0)531 58 000 58 www.aicon3d.dewww.aicon3d.com | info| [email protected]@aicon.de.