how 3D laser scanning services are used for reverse engineering and prototype design
The first step in creating almost any object is to define the 3 dimentional form of its shape. Not that long ago, the conceptual form would be made from wood or clay or some other moldable material. To some extent, the practise still exists today but it’s mostly confined to clay sculpting for car body designs. Engineers, inventors, designers and architechs all use CAD software to convert ideas to the most fantastic structures imagineable but when an existing product needs to be improved for fuction or evolving manunufcturing processes, 3D scanning and CAD modeling is the most efective choice.
A 3D scanned model starts out as thousand or millions of points of data in a space, each point is defined in terms of a the standard Cartesian coordinate system. All the points in 3D space represent a “point cloud”
Point cloud data is then brought into a common reference system where the data is merged into a complete model via the process of alignment and registration. This process can occur during the scan itself (as is the case with the high-end, Creaform laser scanners) or as a post-processing step. The resulting data can be processed further using specialized software, which “cleans up” the scan data by filling gaps in the data (or holes) then connecting the points into triangles forming a mesh or polygonal model. These files commonly have the .STL file extension or Stereolithography.
Some other typical formats for triangle mesh files are OBJ and SAT. These files, once processed correctly, can be 3D printed in a wide variety of processes and materials from plastic to metal to concrete. Scanvik has recently 3D print Diamond! These mesh files, however, are considered “dumb” models. They don’t have any embedded dimentional information and can’t be used for creating meaningful 2d drawings or used in creating G-code (tool paths) for mult-iaxis CNC machining.
The process of taking point cloud data and turning into a useable model (scan-to-cad) also takes special (reverse-engineering) software and expertise. There is no “one button” scan-to-cad conversion that will produce a precise and useful 3D model.
As products get older and wear out or the original manufacturer ceases production or when the technical data, like the drawings are lost, the need for reverse engineering presents as a neccessary soluton. The new approach to reverse enginnering is a process of continous development using 3D scanning and scan-to-model techniques. Testing form fit and function or stress analysis, in most cases, no longer require the part to be fabricated and tested to destruction. Stress analysis software can simulate a part under any design load and parts in close proximatry can be “virtually” assembled. A prototype part can be 3D printed quickly and cheaply prior to entering full production. With ever improving 3d printing processes and materials, printed parts are not only for prototype purposes. many companies have incorporated 3D printing as part of the full production process.
Bluestone 3D laser scanning service
Some benefits of using 3D scanning technology for your next reverse engineering or prototype development project ;
- quickly producey highly accurate scan data of the item or part
- turn scan data (point cloud) into useable CAD models with design intent
- reverse engineering time and cost is drastically reduced over convntional methods
- digitize difficult to measure or organic geometries easily
- quickly produce drawings and reports for manufacturing requirements
- test the design with computer stress modeling prior to production
- make changes to the design quickly and easily
If you have a project that might benefit from our expertise, give us call or email
The incredible inprovements with 3D laser scanning and additive manufacturing (3D printing) over the last few years have made this technology available to more people than ever. If you have any questions about the process of reverse engieering , product inprovement, prototype development or QA inspection, please give us a call or email.
Don’t let the OEM dictate the life of your equipment. If you can’t buy it, build it!