AN INTRODUCTION

TO 3D SCANNING

While the mainstream media continues its obsession with 3D printing, another quiet, perhaps
more impactful, disruption is revolutionizing the way products are designed, engineered, manufactured, inspected and archived. Its 3D scanning -- the act of capturing data from objects in
the real world and bringing them into the digital pipeline.

ACCORDING TO A RECENT STUDY

BY MARKETSANDMARKETS, THE
3D SCANNING MARKET WILL GROW
NEARLY

15%

ANNUALLY OVER THE NEXT FIVE

YEARS, WITH THE
PORTABLE 3D SCANNING SEGMENT
LEADING THE WAY.

Portable 3D scanning is fueling the movement

from the laboratory to the front lines of the
factory and field, driven by the following key
factors:
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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

SCANNED IN 3D FOR

PURPOSES:

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Reverse engineering
GEOMETRICAL
ENTITIES
MESH
CAD

PART

3D
COMPARISON

SCAN

2D
COMPARISON

Inspection

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

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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

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The resulting triangle mesh is typically exported as an STL (STereoLithography or Standard Tessellation Language)
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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. THATS WHY IT IS VALUABLE
TO TAKE A LOOK AT POSITIONING
METHODS WITHIN THE DIFFERENT 3D
SCANNER CATEGORIES.
The main 3D scanner categories:





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CMMs (coordinate measuring machines) and measuring

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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

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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 establish 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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These 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

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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
while white-light devices project a light and shade pattern.
Both will analyze the resulting deformed projections to extract
the 3D data.
POSITIONING METHOD: REAL-TIME SELF-POSITIONING
THROUGH POSITIONING TARGETS, OBJECTS NATURAL
FEATURES/TEXTURES OR HYBRID
Handheld scanners rely on two cameras to create what is
called stereoscopic vision. This enables the device to deWHUPLQHWKHVFDQQHUSRVLWLRQLQUHODWLRQWRVSHFLFSRLQWV
which could be positioning targets, the objects natural
features or textures. Some newer portable scanners use a
mix of positioning types called hybrid positioning.

Advantages
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Limitations
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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.
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improved quality, reduced warehousing costs, and
better understanding of product performance.

In the pages that follow, well explore

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different stages of PLM:






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3D scanning is used in the concept stage of PLM for a wide variety of processes, including determining
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Concept design

Concept prototyping

Concept
Competitive product analysis
Clay model measurement/Reverse
engineering
Measurement of product environment
or connecting/Surrounding parts
Models and mock-ups
measurement/Reverse engineering
Measurement of existing parts for
aftermarket or custom equipment
Styling and aesthetics

Integration of prototype
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Form study, proof-of-concept
prototypes
Ergonomy prototypes

 Our research units include nearly 2,000 researchervs with experimental facilities.

The detailed 3D scans and 3D

D model
allow us to accurately design and
integrate our sideboom attachment
chment
h
onto
the existing platform
form (tractor),
says the vice president
resident of engineering
for Midwestern.

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accurate considerably
onsiderably minimizes the
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make to the platform. It also allows us
to
o completely visualize the design
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Midwest
Midwestern
Manufacturing produces sideboom
pipelayer attach
attachments for new and old tractors from
industry leaders such
suc as Caterpillar, John Deere, Case
and Komatsu. When
Whe 3D models are not available,
Midwestern uses reve
reverse 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 th
sign process
the design
and enables Midwestern to reduce product
dev
develo
elopment time.
development

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

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Reverse engineering
(extracting design-intent)
Packaging design

Rapid prototyping/Manufacturing
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Prototype inspection

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manufacturer of customized parts and vehicles that
specializes in styling, engineering, CAD, FEA, manufacturing, CNC machining, binding and welding.

Considering how often we use our 3D

scanner, and if we add up the work
hours that we are saving, we expect to
get an excellent ROI very quickly.

A motorcycle chassis is very complex and features

irregular shapes; as a result, the conventional methods
irregu
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tedious. Having no access to manufacturers 3D
tedi
powerful reverse engineering solution was
drawings, a p
needed to reduce the production times of CAD drawings.

- According to the president of Zeel Design

3D scanning makes
make it possible to easily and rapidly
obtain a highly accurate 3D
3 images of the assembly and
components at the same timewithout
all of the existing component
having to draw them in 3D. The engineering
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drawings and the reverse
they previously spent on CAD drawi
self-positioning handengineering process. The use of a self-p
played a key role
held laser scanner right in the shop pla
ole
reduce design
in Zeel Design being able to drastically red
esign
project turnaround
turnaround 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

Manufacturing

Reverse engineering of dies, molds,

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tooling measurements
Tooling validation/Inspection

Assembly/Production

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The European Aeronautic Defense and Space (EADS)

company, recently renamed Airbus Group, performs 3D
optical scans of tooling equipment to assess the posVLEOHJHRPHWULFGLVWRUWLRQRIFDUERQEHUFRPSRVLWH
(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 manufactured with this tooling are scanned, and the scanning
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seco step consists of using very powerful simulation too
tools to estimate the distortion of the parts beIRUHPDQXID
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of the manufacturing parts.
The versatility of a portable 3D scanner made it the
tool of choice for this ta
task, both in its capacity to scan
h
unorthodox shapes, handle
hard-to-scan materials,
tly
such as composite parts, and perform scans directly
on the projects site.

Thanks to its quick set up and

acquisition, ease of use, measurement
performance for many types of surface
states, and portability, the system
enabled us to quickly scan the metallic
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parts. The equipments portability made
it possible for us to record the
measurements right at the
manufacturing site.
A member of the EADS Structure Health
Engineering (NDT & SHM) Department

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When it comes to manufacturing using molds and

dies, what you get is not always what you created in
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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 complicated to match the actual die or mold to the CAD
geometry.
wher portable 3D scanning comes in: 3D scan
Thats where
provide insights into deviations that might ocdata provides
m
cur during mold
and die production. The ability to
moni die and mold geometry and the
accurately monitor
corresponding parts it produces helps reduce design
iterations, saving time an
and resulting in parts that more
e.
accurately match the CAD reference.

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.

Documentation

Maintenance, repair and

overhaul (MRO)

Servicing

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parts/Tooling
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Replacement/Recycling

Reverse engineering for developing

replacement/Restoration parts
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Atlas Weyhausen, a manufacturer of wheel loaders

and other heavy equipment, uses a portable 3D scanner to measure components and equipment for quality
assurance and for data feedback from prototype parts.
The company saves time and money from the increasing number of situations where components must
be inspected at their installed location or recorded
abroad at the suppliers location.
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time for quality comparisons.

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easy
asy to see,
says an Atlas quality assurance
surance manager.

Freeform surfaces are easy to align,

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the data feedback into our CAD system.

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
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existing consumer products, including toys, accessories
and apparel.
Custo
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design.

A full range of app

applications can be found in the
Creaform website.








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Milwaukee School of Engineerings (MSOE) Rapid

Prototyping (RP) Center modeled a time capsule from
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jug. The time capsule was a central part of Face Jugs:
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exhibition that originated at the
Milwaukee Museum of Art.
The original face jug -- about the size of a grapefruit
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containing target d
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ating.
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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

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