3D Scanning & Applications

INUS Technology, Inc.May, 2008

Calvin J. HurSenior Vice President, Marketing & Global Sales

© 1998-2008 INUS Technology, Inc. and Rapidform, Inc. All rights reserved.

What is 3D scanning?

Geometry Capturing Device

• Conventional Approaches

–Tactile methods

–Laser type (Time of flight type)

• Emerging Approaches

–Non-contact methods

–3D scanner, 3D digitizer, etc.

CMM vs. 3D Scanning

CMM( ~ 1990 )

CMM as a standard &

3D scanner debut( ~ 2000 )

3D scanner penetration( 2000 ~ )

• CMM : Point-level measurements

ex) One point / 0.5 sec

• Main application: Quality inspection

• CMM vendor: Zeiss, Hexagon, Mitutoyo, etc.

• 3D scanner: Point-cloud-level measurements

ex) 4 Mega points / 1 sec

• Main application: Reverse engineering & quality inspection

• 3D scanner vendor: Breuckmann, Steinbichler, Minolta, etc.

CMM 3D Scanner

Advantages• Low price

• sub micron accuracy

• High density points

• Quick measurement

• Portability

• Wide applications

Disadvantages• Low density points

• Long lead time

• Fixed measuring volume

• High price

• 3 micron MAX accuracy

Main applications

• Accurate inspection

• Some reverse engineering

• Quality inspection

• Reverse engineering

• Non-CAD reverse engineering

3D Scanning Device: 1. Light Source

projector

CCD- camera

Triangulation angle

Pattern Projection

Laser Projection

3D Scanning Device: 2. Projection Type

Long-range 3D ScannerTime-of-Flight

• Big object (landscape, building, plant, etc.)

• Time-of-Flight method

• Surveying & cultural heritage applications

Leica GeosystemsScanStation

3D Whole-body Scanner

WB4, CyberWare

2T4, ImageTwinVoxelan, Hamano

BL scanner, Hamamatsu

Vitus Smart / Pro, Victronic SYMCAD, Telmat

NX, TC2

3D Scanning Software

Cultural Heritage

Medical & DentalMass customization

Computer Graphics Industrial CAD Reverse Design

Quality Inspection

What is 3D scanning used for?

3D Scanning Applications

Reverse Design (Redesign/Reverse Engineering) No CAD – Generate parametric CAD models of physical parts that lack documentation.Sync. CAD – Sync a digital CAD model and a physical prototype, removing the disparity from-hand operations, die-tryouts and design iterations.Clay to CAD – Hybrid surface and solid modeling capabilities of Rapidform XOR allow for the creation of parametric CAD models from scan of physical mock-upsBenchmarking – Once a CAD model has been generated from the 3D scan data, engineers can use the model for a variety of applications including analysis, machining and further modification in SolidWorks, Pro/Engineer and UGS NX.Geometry Recovery - Tools, dies and other parts can lose their defining features through wear or can deviate from the original CAD model through shop-floor modifications.Custom made Products – Effective one-of-a-kind product manufacturing customized for individuals.Medical & Dental – Rapidform XOR can clean up raw 3D scan data of anatomy and automatically generate extremely accurate NURBS surface models.

Quality InspectionWith Rapidform XOV, designers, engineers and QA experts can compare CAD design data to scanned parts, as well as perform a variety of GD&T (Geometric Dimensioning & Tolerancing), and create detailed inspection result reports. Inspection results can be shared with colleagues and customers using standard formats (PDF, Excel, Word, Text, XML, etc.), in interactive 3D over the Internet, or using Rapidform's free plug-in for Microsoft Office.

Cultural Heritage Rapidform offers the most comprehensive set of tools available to ensure an accurate, detailed and easily stored, shared & measured 3D model preserving all acquired color information.

Surveying, AEC, Computer Graphics and others

Reverse Engineering

Application #1

What is Reverse Engineering?

Shape (Geometry)Functionality

“Rebuild”“Reconstruction”

“Copy”“Duplicate”

Reverse Engineering Applications

경쟁사 제품 분석

수작업 이후 대량 생산 실제 제품의 설계 해석

기존제품 CAD화

Aftermarket 단순 제품 복제

양산제품과 CAD와의 이격 보완

Where does CARE fit in manufacturing process?

Industrial design

CAID

Clay ormock-updesign

Part design adjustment

M-CADCAE

analysis &simulation

PrototypeMfg.

Mold patterndesign & mfg.

Assembly design adjustment

Assemblymodeling

Productionprocessplanning

Competitorsparts

Partsfrom

suppliers

Mass production

Massproduction

CARE: Computer Aided Reverse Engineering

Here

Here

Here

Here

Here

5 hours to scan(including scan data processing)

4 hours to redesign(previously a week)

XOR compensates gap between CAD and actual die• CAD-to-Die design gaps as a result of manual modification over tryouts • Helping user discover & capture design parameters from actual die• CAD-to-Scan redesign (refit) at your finger tips• Dramatically saving time and cost; 90% over conventional way• Revolutionary automated process with replacing tedious labor

Reverse Engineering-1:GM (US)

Mold Duplication using 3D Scanning

Scan Data Feature Extraction

Solid Modeling

Reverse Engineering-2: Delphi (US)

Reverse Engineering-3: Boeing (US)

Blade

Slicing curve by cylindrical section Add-in

Ref. CylinderIntersection bet. Blade & Cylinder

Reverse Engineering-5:YAMAHA MOTOR (JAPAN)

Polygon model

Surface model

FAA-PMA aircraft part repairing and replacement• Helping user discover & capture the original design intent & parameter• Saving time and cost; 60%-80% over 1st and 2nd generation work flow while

staying in the allowable deviation range• Result is a parametric & manufacturable CAD model with its pristine design

condition; as it was intended to be.

2.5 hours to scan(including scan data processing)

1 hour to model(previously 10 hours)

Reverse Engineering-5:LUFTHANSA (Germany)

Rapid Inspection

Application #2

Systematic Inspection Process

• Standardizing quality specification• Quality check on delivery

• Production tool quality check• First article inspection

• Design prototype validation

• Tool modification & quality check• Shop floor production line inspection

• 100% or sample inspection

Scan data

Section View

Section ViewSide View

2D Drawing

2D Drawing

Rapid Inspection-1:Greenleaf Corp. (US)

Whole deviation

Section deviationSection Curves

Dimensions

Rapid Inspection-2:Shimano (JAPAN)

2D Drawing

3D Section and Dimension

Rapid Inspection-3: Boeing (US)

Rapid Inspection-4:Rautenbach (Germany)

Industrial CT Scanner-based Inspection

Rapid Inspection-5:HONDA (US) & GM (US)

Surface Dent Inspection System

Rapid Inspection-6:Chassis Inspection Case (RICOH)

Inspection Target Setting (Semi Auto)2

3D Scan3

Inspection Result (Auto)4

CAD Design1

Rapid Inspection-7:Sheet Metal Inspection (Daimler Chrysler)

Rapid Inspection-8:Inline Inspection: Honda

Scan data

CAD data

CAD/Scan data Align

Hole inspection

Rapid Inspection-9:Automotive Parts Inspection (TOYOTA)

CAD data

Scan data

Whole Deviation

Rapid Inspection-10:Road Inspection (YOKOHAMA)

• Analysis of the micro structure of the tarmac before and after a race

• Data are used to improve the design of tires

Mobil use of µicroTOP-zoom road measurement

3d-model of tarmac

surface

Surface measurement

Mass Customization

Application #3

Mass Customization-1:Wacoal (JAPAN)

3D Scanning Phase

Customer

3D Scanning

3D ScannerSystem Software

Data Processing SoftwareFrom raw scan to fine data

PolygonOptimization

Simulation Phase

3D Model Databse of Bra

simulation ModelCreation

AnalysisComparisonMeasuringSize Try-on

Recommendation

Purchase&

Side services

Virtual SimulationVolume & Shape

Virtual try-on(Matching)

A

B

Scanning Center 2D Pattern DesignKey Dimension

Extraction

Virtual Try-on

Size Recommendation

Manufacturing

Apparel CAD/CAM System

Mass Customization-2:LECTRA (FRANCE)

Mass Customization-3:SOCIE (JAPAN)

Mass Customization-4:Realadi & Hanger (US)

Scan

Mass Customization-5:NECO, Inc. (US)

Mass Customization-6: Hearing Aids

Heritage

Application #4

Heritage-1: Altamira & Salin Cave (SPAIN)

Heritage-2: Angkor Wat (CAMBODIA)

Heritage-3: S.I.T. (Spain)

Heritage-4: 3-Dimensional Analysis: Paintings

La Joconde (Mona Lisa), Louvre, Paris

Measurement task: scanning of a painting,

Louvre

simultaneous capturing of 3D and colour

information

documentation the current status of the

painting

scientific analysis of characteristic techniques

of the artist

to investigate the state of the canvas,

detection of hidden damages and deformation

measurement

Measuring system : optoTOP-VI

Field of view 175 mm

camera with 6,6 MegaPixel

X/Y resolution : approx. 45 µm

feature accuracy : approx. 3 µm

Heritage-5: Preservation of historical monuments “Residenzbrunnen”, Salzburg, Austria

• Measurement task: Generating data for documentation and archiving purposes and for scientific studies.

• Measuring time: approx. 3000 single scans for the whole fountain 6 weeks.

• Size of the object: diameter 15 m and height 12 m

• The digitised sculptures allow conclusions on the structural status of the art objects; an archiving and documentation of cultural objects is possible

The Residenzbrunnen in

Salzburg

3D-data plus texture

Medical & Dental

Application #5

Conventional way

Using 3D scanning

Medical & Dental-1:University of Houston (US)

Medical & Dental-2:InvisAlign (US)

1. Initial ModelsOriginal & Target

Optimize polygon

2. Intermediate Models for Aligning TeethPolygon morphing

Automatic generation of intermediate shapes

3. Dental SimulationReal-time collision detection

Interference analysis

Original Target

Step.1 Step.2

Medical & Dental-3:Schutz (Germany)

Raw data Registration MergingHealing &

optimization

Medical & Dental-4: TU of Munich (Germany, Swiss)

Medical & Dental-5: Harvard University (US)

Medical & Dental-6: Johnson & Johnson (US)

• Pre-Post comparison

• Cosmetic effect analysis

• Pre-Post comparison

• Botox effect analysis

Medical & Dental-7: ORA (US)

Computer Graphics

Application #6

Computer Graphcis-1:Gentle Giant Studio (US)

Computer Graphcis-2:Crystal Works (UK)

Topic:CATIA IGES RapidForm LWO LightWave Rendering

Computer Graphcis-3:Chrysler (US)

Thank You !For more information, visit our web site at www.rapidform.com