<p>You work in transportation, energy, aerospace, mining, or heavy industries. You manufacture large parts and assemblies, some with black or shiny surfaces. You want to measure these large parts with high accuracy and fine detail without having to move them from their production environment. And, above all, you don’t want to siphon off all your budget. If these sentences describe you, the blog below will surely be of interest.</p><h2 id="isPasted"><strong>It’s Hard Enough to Manufacture Large Parts…</strong></h2><p>Manufacturing and assembling large parts involve several challenges that are not present in the fabrication of smaller, lighter components. Specifically, oversized parts are produced in <a href="https://www.creaform3d.com/en/solutions/measuring-impeller-turbines-harsh-manufacturing-environments" target="_blank">harsh environments</a> where oscillations, vibrations, and thermal variations are ubiquitous. These parts are often heavy and bulky, which means a single human cannot move them easily.</p><p>As these parts have larger surface areas, their fabrication processes may require additional quality checks to locate and fix deviations and distortions promptly before these errors are magnified or multiplied. In fact, these inspection steps are crucial for <a href="https://www.creaform3d.com/en/applications/3d-scanning-improve-quality-control-additive-manufacturing-processes-large-parts-0" target="_blank">maintaining quality standards</a> throughout the manufacturing process and achieving strict tolerances.</p><p>The same challenges arise when it comes to developing, producing, and installing replacement parts that have suffered damage or wear, as well as <a href="https://www.creaform3d.com/en/3d-scanning-auto-oe-and-aftermarket-sectors" target="_blank">aftermarket parts and accessories</a> designed to enhance vehicle performance, comfort, or safety. These newly built parts that can reach significant sizes must be designed to seamlessly adapt to and easily fit with the equipment already in place without necessarily having access to the CAD files of the platform where the parts will be attached. At this large scale, aftermarket manufacturers need sufficient accuracy and adequate resolution to avoid fitting issues, project delays, and additional costs. Consequently, they must have a measuring method that allows them to find the perfect fit on the first try.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1700643924924-HandySCAN-MAX_Scanner_Loader-base_Side-view_Rotobec-1+%281%29.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">Engineer scanning a massive and complex part with the Creaform HandySCAN 3D|MAX Series in a production environment</span></span></span></p><h2 id="isPasted"><strong>It Shouldn’t Be Harder to Measure Them</strong></h2><p>Until now, nothing was well-suited and affordable for measuring large parts on the shop floor. Methods for scanning large parts did not have the required accuracy and resolution. Those that could offer precision only measured specific probing points, not entire surfaces. Anything that could scan 3D surfaces with good accuracy was simply unaffordable. And products that could provide affordable long-range surface measurements did not meet the accuracy standards. Further complicating the process, contrasting and reflective surfaces were hazardous to measure with optical technology.</p><p>In short, measuring large parts and complex 3D surfaces with a handheld device was previously laborious and challenging or, in some instances, even impossible.</p><p>Thankfully, the situation has now changed with the new CREAFORM <a href="https://www.creaform3d.com/en/handyscan-3d-max-series-for-large-objects" target="_blank">HandySCAN 3D|MAX Series</a>.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1700643952777-HandySCAN-MAX_Scanner_Rotobec.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">New Creaform HandySCAN 3D|MAX Series used on the shop floor for measuring large parts</span></span></span></p><h2 id="isPasted"><strong>The Creaform Solution to Accurately Measure Large Parts</strong></h2><p>The new MAX Series possesses all the attributes that made the&nbsp;<a href="https://www.creaform3d.com/en/portable-3d-scanner-handyscan-3d" target="_blank" rel="noopener">HandySCAN 3D</a> line-up the go-to approach for the industry—portability, speed, accuracy, and simplicity; on top of that, Creaform has added an extra-large measuring volume. And all this is enhanced with blue laser technology, integrated photogrammetry, and live meshing.</p><p>This means that you no longer have to move these heavy and bulky parts to measure them, as the HandySCAN 3D performs the scanning session right on the shop floor.</p><p>Featuring dynamic referencing and volumetric accuracy optimization, the MAX series is engineered to work in harsh environments while delivering high accuracy on large measurements, regardless of the user’s experience level. With its ISO 17025 accreditation and compliance with the VDI/VDE 2634 Part 3 standard, you get metrology-grade results for your quality controls with tight tolerancing. Its 38 blue laser lines offer better performance and deliver better readings of difficult, contrasted surface finishes while allowing you to scan large parts and assemblies—up to 15 m (50 ft)—in just a few minutes. In addition, its large scanning area—up to 1.8 x 1.8 m (70.87 x 70.87 in)—allows you to scan vast surface areas rapidly.</p><p>Trucks, impeller turbines, castings, airplanes, heavy machinery, and more can now be measured quickly and easily with the new CREAFORM HandySCAN 3D|MAX Series.</p><p>Watch Creaform scan an entire minivan with high-resolution data in just a few minutes.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/BiyXWALbFaA?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted"><strong>Three New Key Features</strong></h2><p>The MAX series also offers new key features developed by Creaform engineers to simplify your scanning process, improve the scanner’s performance on difficult surfaces, and provide the flexibility to scan both at a short distance with fine detail and from a longer distance at high speed.</p><h3><strong>1.Flex Volume</strong></h3><p>The Flex Volume feature allows you to choose from multiple scanning modes based on whether you value fast speed, maximum resolution, or speed without compromising resolution. With the 3D scanner in hand, you have the flexibility to scan large parts at very high speed from a longer distance (Far Mode) or measure smaller areas with remarkable quality at a short distance (Near Mode). A nominal mode is also available to enable you to benefit in terms of both speed and resolution.</p><p>See the Flex Volume in action.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/ub_FEkNhQI8?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h3 id="isPasted"><strong>2.Real-Time Calibration</strong></h3><p>With the Real-Time Calibration feature and the guidance of two scale bars, the 3D scanner adjusts its internal components during the scan, integrating the calibration step directly into the scanning workflow. There is no need for any extra calibration steps; everything is done automatically and seamlessly. The use of these scale bars guarantees the best accuracy for large parts and assemblies.</p><p>See how the Real-Time Calibration works.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/eY1RZYxGXic?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h3 id="isPasted"><strong>3.Smart Surface Algorithm</strong></h3><p>The Smart Surface Algorithm feature optimizes surface measurement with its sophisticated image processing combined with artificial intelligence. This means that the MAX series offers better performance and better readings of difficult contrasting finishes, which means that you can enjoy a simpler and more straightforward scanning process.</p><p>Watch as Creaform scans shiny finishes with the Smart Surface Algorithm.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/SYLhtVIWGwo?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted"><strong>Measuring LARGE Parts Is Now Faster and Easier Than Ever</strong></h2><p>With the game-changing HandySCAN 3D|MAX Series, Creaform opens up new opportunities by making possible the large-scale scanning of parts that were previously challenging, if not impossible, to measure.</p><p>This plug-and-play, quick-to-install, and easy-to-learn measuring system is engineered to capture fine details and scan large volumes equally well, providing you with high-resolution 3D scans of large parts in just a matter of minutes.</p><p>Without a doubt, the MAX Series’ new key features and sophisticated algorithms make scanning large parts with difficult surfaces simpler than ever. Your&nbsp;<a href="https://www.creaform3d.com/en/applications/product-development-with-3d-scanning" target="_blank" rel="noopener">product development</a>,&nbsp;<a href="https://www.creaform3d.com/en/applications/reverse-engineering-with-3d-scanning" target="_blank">reverse engineering</a>, and&nbsp;<a href="https://www.creaform3d.com/en/applications/quality-control-and-assurance-with-3d-measurement-technologies" target="_blank">quality control</a> processes will only improve. Ultimately, the most significant enhancement will be visible on the faces (and smiles) of the people performing the scan.</p><p>If you manufacture large parts, you should have a look at the new CREAFORM HandySCAN 3D|MAX Series.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/yxcsZ6OalQ4?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span><br></p>

Engineer scanning a gigantic part with the Creaform HandySCAN 3D|MAX Series

You work in aerospace, transportation, energy, mining, or heavy industries. You manufacture large parts and assemblies, some with black or shiny surfaces. You want to measure these large parts with high accuracy and fine detail without having to move them from their production environment.

Do You Have Trouble Measuring and Analyzing Large Parts?

<p><a href="https://www.nexans.com/en/" target="_blank" id="isPasted">Nexans</a> is leading the charge to the new world of electrification. The group is a leader in designing and manufacturing cable systems and services across several business areas, including energy generation &amp; transmission, distribution &amp; usages, industry &amp; solution projects, harnesses and telecom infra. The company continuously develops innovative services and solutions from its long-standing expertise in cabling and electrical systems.</p><p>With nearly 25,000 employees, Nexans operates in over 40 countries and is on track to transition to 100% of electricity coming from renewable sources, with the goal of contributing to carbon neutrality by 2030.</p><h2 id="isPasted"><strong>High-voltage equipment inspections: Critical to preventing component failure and outages.</strong></h2><p>In the high-voltage (HV) sector, component failure can come at tremendous costs; instant local asset outages of up to 2 GW can occur, which can cause a loss of power transfer capacity equivalent to several nuclear reactors all at once.</p><p>This is why Nexans has implemented a comprehensive quality control programme for the preparation and on-site assembly of new installations, as well as regular preventive maintenance inspections for existing installations.</p><h3><strong>Manual inspections miss out on smaller defects</strong></h3><p>Traditionally, the inspection of HV cable accessories, such as joints and terminations have been inspected manually, relying on the visual acumen and expertise of technical operators.</p><p>However, as innovations in HV cable accessories developed over the years, geometries have become increasingly complex. While manual inspections could assess the overall geometry of a component, such as ovality and the entire shape of the insulation surface, it became increasingly difficult to detect small features, like dents, nicks, scratches, faults, and contaminants.</p><p>Nexans therefore developed a proprietary platform, <a href="https://www.nexans.com/en/business/power-generation-transmission/subsea-interconnectors/Nexans-SURFICAL.html" target="_blank">SURFICAL</a>, to automate visual inspections, bringing additional accuracy and reliability to the quality control process and enabling teams to document and archive each inspection.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1700132305379-Picture1-3.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">Inspection, computation and output generation steps of SURFICAL. The core of the on-site inspection is to generate GO/NOGO criteria on many geometric aspects for both big and small features.</span></span></span></p><h3 id="isPasted"><strong>3D scanning: A game changer for high-voltage equipment inspections</strong></h3><p>Nexans’ quality control team decided to scout out new technologies to eliminate the constraints associated with manual inspections.</p><p>For Nexans the turning point to introduce this technology was their improved knowledge on how high voltage direct current (HVDC) dielectric properties link with surface preparation and the surface geometries created on job sites. Furthermore, Nexans noticed how laser scanning technology evolved over time, triggering the need to examine different commercial products.</p><p>While many scanning solutions are available, it was understood that both high resolution and accuracy were needed to map the smallest of surface defects. While inspections of macro geometries are important, they alone do not fully complete quality control for high voltage products, where small defects can cause local enhancement of local electric field strength. Local field enhancement can cause initiation of electric insulation degradation processes that deteriorates the material and ultimately lead to failure of the manufactured products.</p><p>Nexans noticed that most products on the market were either focused on small-domain scanning at high resolution, using stationary setups (such as optical profilometry), or on large scales and lower resolution (such as LiDAR and photogrammetry).</p><p>However, when the team came upon Creaform’s 3D scanning technologies, namely the <a href="https://www.creaform3d.com/en/portable-3d-scanner-handyscan-3d/technical-specifications" target="_blank">HandySCAN BLACK|Elite</a>, the quality control experts knew they had found a solution.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1700132343173-Picture2-4.webp" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Laser scanning was found to provide an excellent middle-ground between technologies, all while being very easy to work with. The Creaform family of products has been clearly identified as being at the forefront of this technology.</p><p>The HandySCAN BLACK|Elite suited Nexans’ needs perfectly, as it is a scanning solution that can provide unprecedented accuracy and resolution, as well as high data acquisition rates and versatility for all HV accessories.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1700132361986-Picture3-1.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">Live adaptations and inspection of mesh are feasible. Given the system’s high accuracy and resolution, the smallest aspects, such as a dust particle shown here, become visible.</span></span></span></p><h3 id="isPasted"><strong>Nexans’s future plans with 3D scanners from Creaform</strong></h3><p>After initial implementation, testing and fine-tuning of inspection workflows, Nexans is ready to roll out the solution to an industrial scale.</p><p>The HV industry is characterized by large-sized components, high unit costs, high variability and unwavering focus on quality and reliability. This industry is ideal for 3D measurement technologies, like Creaform, as a means to push the frontier of quality control. Nexans will initiate many more similar innovations in the future.</p><p>Nexans sees this technology as a game changer for the QC of on-site preparation and assembly activities in HV cable accessories.</p><p>As stated by one of our R&amp;D engineers: “Anyone’s reaction when first using a Creaform scanner is filled with amazement. That’s when we tell them;&nbsp;<em>Welcome to the future</em>!”</p>

Laser scanning was found to provide an excellent middle-ground between technologies, all while being very easy to work with. The Creaform family of products has been clearly identified as being at the forefront of this technology.

Electrifying the future with 3D scanning technologies

<p>End-to-end manufacturers are companies that lead products through the entire manufacturing process, from design to customer delivery. Unlike businesses that manufacture their products with a segmented manufacturing process, end-to-end manufacturers have complete control over the different parts of production, which ultimately impacts the time, money, and effort associated with product innovation and time to market.</p><p>But what about product quality? What practices can end-to-end manufacturers adopt to increase quality and deliver high-end products to their customers? Considering that they control the entire manufacturing process, how can they judiciously use quality data from one step to enrich the next? This blog seeks to answer these questions.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699491320275-Factory-of-tomorrow-End-to-end-manufacturing.v1.jpg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">heavy automation robot arm machine in smart factory industrial,Industry 4.0 concept image.</span></span></span></p><h2 id="isPasted">The Challenges of End-to-End Manufacturers</h2><p>Nowadays, competition is strong. Customers demand quality, and they want it delivered at a reasonable price. The market eagerly awaits the launch of new products that are both innovative and attractive. Products must function without any defects for an indefinite period while being continuously improved and updated.</p><p><a href="https://www.creaform3d.com/blog/the-challenge-of-following-the-short-cycle-time-of-mass-production-with-inline-inspection/" target="_blank">These requirements put untold pressure on manufacturers</a>, who must use all possible stratagems to increase quality, reduce costs, limit downtime, accelerate time to market, enhance innovation, and beat competition. Considering these daunting tasks, manufacturers are surely wishing the blue genie will emerge from his bottle and grant a lot of wishes.</p><p>What if the parts are large, complex, and require a long manufacturing process involving several steps? How can end-to-end manufacturers gain efficiency and limit rework in such a context?</p><p>The same challenge applies to product development processes that require several iterations, such as the design process for a composite cutting jig. How do you develop a prototype corresponding to CAD requirements while limiting the number of iterations?</p><p>The key is measuring the prototype a few times to adjust the jig and then adding or removing the missing or extra millimeters accordingly. Thus, even before the start of production, the quality boost obtained from scan data and rework is transmitted from one stage to the next, allowing end-to-end manufacturers to gain efficiency while improving quality.</p><p>This same logic applies to all manufacturing processes involving complex and expensive parts. Inspection results are sent to another stage of the process, either via a machine or a human, to correct imperfections and improve quality. After all, throwing away such valuable parts that took so long to manufacture would be unthinkable, even if they do not meet tolerances at first glance.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699491346724-Assembly-line-in-a-car-factory-1536x1024.jpeg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">Assembly line production of new car. Automated welding of car body on production line. robotic arm on car production line is working</span></span></span></p><h2 id="isPasted">Quality Control Solutions Maximizing Product Development and Manufacturing Processes</h2><p>Design and production engineers rely on top-quality control technologies and software solutions to help them maximize their product development and manufacturing processes.&nbsp;<a href="https://www.creaform3d.com/blog/learn-how-to-leverage-the-potential-of-automation/" target="_blank">Automated quality control is the solution</a> that will enable them to inspect part dimensions accurately and then transmit the acquired data to other machines so that the manufacturing process can be adjusted accordingly. The goal is to produce high-quality parts that meet customer requirements and deliver them on time, without delay or defects.</p><p>But what criteria must these solutions satisfy to guarantee end-to-end manufacturers better manufacturing and product development processes?</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699491383406-MetraSCAN-R-BLACK-HD_car-frame-inspection_color-map-1536x1024.webp" style="width: 766px;" class="fr-fic fr-dib"></p><h2 id="isPasted">Quality Control Automation Tools</h2><p>Automated measuring tools must take into account the type of part being measured. A technology for measuring any part without preparation, regardless of its size, geometry, or surface finish, can be integrated into the manufacturing process at any stage without altering its flow.</p><p>By this very fact, the speed of the quality control tool must also be considered. An instrument allowing for the acquisition of innumerable measurement points quickly, such as a 3D scanner mounted on a robot, will comply with the required cycle time, even if the part’s geometry is complex and its surface difficult to measure.</p><h2>Automated Quality Control Software</h2><p>An offline simulation platform offering an environment very close to reality will be able to replicate the behavior of a real 3D scanner and give a more precise evaluation of the cycle time. In addition to the ability to program robot paths in any configuration for a large category of robots, such simulation platforms will also detect whether the robot trajectory must be modified in the event of a risk of collision.</p><p>Moreover, the chosen acquisition platform should offer an integration capacity with external metrology software, such as Polyworks or Metrolog. Thus, when the acquisition is completed, the scan data can be automatically transferred to the inspection software to improve the following steps in the manufacturing process and raise product quality.</p><p>Finally, the supplier who develops both the 3D scanners and the acquisition platform will ensure that the best possible data is generated during the acquisition and during the reconstruction of the surfaces in digital format. The algorithms will be optimized to provide the best possible resolution so that difficult surfaces and large objects can be scanned with the right level of detail.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699491401783-cube-r_automated-3d-scanning-cmm_user-vxscan-r-1536x1024.webp" style="width: 766px;" class="fr-fic fr-dib"></p><h2 id="isPasted">How to Implement Automated Quality Control Processes</h2><p>Nevertheless, implementing automated quality control processes is a long and expensive path, and choosing the best automation tools and the most suitable acquisition and simulation software platforms are just two of the many tasks ahead. So, where to start? Here are the best practices to guide you on your journey.</p><h2>Best Practices for Automated Quality Control</h2><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699491427067-Industrial-robots-1536x884.webp" style="width: 766px;" class="fr-fic fr-dib"></p><h3 id="isPasted">#1 Do a financial analysis of the first-year savings.</h3><p>Before considering which automated quality control system could best suit your needs, you must decide which manufacturing task can be replaced by an automated solution. Consequently, you must know if the project is viable financially. Will there be savings on direct labor? Can you reduce rework and make gains by limiting the scrap rate since defects will be identified earlier in the process? Can the necessary floor space be reduced? Will the new tasks assigned to employees be more rewarding and increase retention? Can productivity be expected to increase, leading to an increase in customer satisfaction and demand?</p><p>To guide you, Creaform has prepared a&nbsp;<a href="https://tools.creaform3d.com/en/calculator/?type=marketing" target="_blank">calculator to estimate the first-year savings</a>. The results obtained will guide you on the type of solution to choose – a turnkey solution or one developed by a robot integrator.</p><h3>#2 Do a project evaluation with offline programming software.</h3><p>A simulation made in a digital twin environment will enable you to verify if the robot is large enough to scan all the surfaces properly. Following this reachability assessment, you can evaluate the cycle time and confirm whether it meets the requirements. As previously established, choosing the most realistic simulation platform will&nbsp;<a href="https://www.creaform3d.com/blog/automated-quality-control-best-practices-for-end-to-end-manufacturers/INSPECTING%20COMPLEX%20AEROSPACE%20PARTS%20WITH%20EASY-TO-USE%20METROLOGY%20SOLUTIONS" target="_blank">facilitate this task and give confidence to the people involved</a>, even those unfamiliar with robots and 3D scanning.</p><p>Following Best Practices #1 and #2, you will be able to assess whether your automated quality control project makes sense financially and virtually.</p><h3>#3 Do a technology analysis.</h3><p>Now, it is time to&nbsp;<a href="https://www.creaform3d.com/sites/default/files/assets/brochures/files/R-Series_Brochure_EN_HQ_20221026.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">validate the technology</a>. When measuring an object with already known dimensions, you must determine if the solution meets the performance requirements. Do the accuracy, repeatability, and resolution conform to the specifications? What about the technology’s ability to scan difficult surfaces without preparation? Does the real cycle time correspond to the simulated one?</p><p>A good practice is first validating the performance requirements using a handheld device directly in the manufacturing environment. This way, the 3D scanning technology can be analyzed beyond its automated context simply by focusing on the technical parameters. Then, once the technology has been validated, it can be put on a robot or in a turnkey solution.</p><h3>#4 Choose the right robot integrator.</h3><p>Since automating a quality control process is often a large-scale undertaking, choosing the right partners is one of the most recommended practices. The integration of the complete solution must be flawless; even if the technology perfectly meets the requirements, the simulation is realistic, and the solution makes sense financially. Otherwise, no one wins – neither the manufacturer of the metrology equipment nor the end-to-end manufacturer nor the client.</p><p>If finding the right robot integrator turns out to be complicated, an interesting alternative for end-to-end manufacturers is to opt for a turnkey solution.</p><h3>#5 Write the business case for the complete solution.</h3><p>Here, the initial financial analysis materializes and indicates whether the return on investment (ROI) makes sense for the organization. Only then can the green light for the project be given.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699491452534-MetraSCAN-3D-R-with-casted-parts-on-turntable-1536x864.webp" style="width: 766px;" class="fr-fic fr-dib"></p><h2 id="isPasted">Automated Quality Control: The Path to Follow for End-to-End Manufacturers 6 parts on a turntable inside a factory.</h2><p>Since they control the entire manufacturing process, end-to-end manufacturers can benefit from automated quality control by judiciously using the quality data from one step to enrich the next, especially in producing large, complex parts with difficult surfaces. In that way, they are assured greater efficiency and limited reworking, ultimately delivering products of higher quality to their customers.</p>

Assembly line production of new car. Automated welding of car body on production line. robotic arm on car production line is working

End-to-end manufacturers are companies that lead products through the entire manufacturing process, from design to customer delivery. 

Automated Quality Control Best Practices for End-to-End Manufacturers

<p>The shipbuilding industry is a critical component of any country’s infrastructure and economy. However, the process of ship construction, particularly the installation of pipes throughout the hull, is challenging and cumbersome. This is due to the segmented construction method adopted in shipbuilding, which often leads to deviations in the hull production process, making it difficult to accurately arrange and install pipes.</p><p>Currently, most shipyards in China rely on manual, labor-intensive, and inefficient techniques for measuring and producing closed tubes, leading to material waste and unsafe working conditions. One Chinese shipbuilder decided to explore alternative technologies to address these manufacturing issues.</p><h2 id="isPasted"><strong>Assessing the precise challenges in hull construction workflows</strong></h2><p>The company explored the conventional tools it was using, such as pull ropes, photogrammetry, and a laser tracker. Acquiring tube measurements were time-consuming, inaccurate, and inefficient, especially in confined spaces with dense pipes. These processes required extensive preparation, installation, and dismantling of equipment, often taking a whole day to measure just 12 pipes in a hull.</p><p>Furthermore, the design process did not allow for multi-pipe routing and spatial location coordination, leading to potential problems that were not uncovered until the construction stage, which ramped up material waste.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1697713270560-Picture1-1-1024x720.webp" style="width: 766px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>HandySCAN 3D|BLACK Series: A game-changer in shipbuilding</strong></h2><p>The company evaluated various 3D measurement technologies and decided to implement the HandySCAN 3D|BLACK Series 3D scanners into its manufacturing process.</p><p>The production team used the HandySCAN 3D|BLACK Series to quickly capture 3D measurement data of the flanges at both ends, connect them through common data of the bottom and wall, and save the data in .STL right after scanning.</p><p>With 11 blue laser crosses to cover a wider scanning area, an accuracy of 0.025 mm, and capacity of 1,300,000 measurements per second, the shipbuilding development team was able to carry out batch measurements to design multiple pairs of folded pipe flanges in a limited space. The 3D scan data was then imported into the dimensional inspection software, including Creaform’s dimensional inspection software module VXinspect for further analysis and processing.</p><p><a href="https://www.creaform3d.com/blog/pun5th75ef_wp/wp-content/uploads/Picture6.jpg" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1697713285760-Picture6-1024x692.webp" style="width: 766px;" class="fr-fic fr-dib"></a></p><h2 id="isPasted"><strong>Achieving unprecedented production efficiency and cost savings with 3D scanners</strong></h2><p>Thanks to HandySCAN 3D|BLACK Series, the company managed to reduce 3D measurement times drastically, from a whole day to just 20 minutes, including the preparation time. It also allowed for visual checks of material levels, surface treatments, flange standards, and effective control of pipe routing during the design process. This integrated solution sped up closed tube production and facilitated better coordination of spatial layouts in the hull.</p><p>“We are very pleased with the HandySCAN 3D in our processes,” explained the shipbuilder’s operations manager. “Creaform’s integrated solution helped us achieve productivity gains—all while minimizing errors and material lost caused by the traditional 3D measurement solutions.”</p>

The shipbuilding industry is a critical component of any country’s infrastructure and economy. However, the process of ship construction, particularly the installation of pipes throughout the hull, is challenging and cumbersome. This is due to the segmented construction method adopted in shipbuilding, which often leads to deviations in the hull production process, making it difficult to accurately arrange and install pipes.

3D scanners: Improving shipbuilding production workflows

<h2 id="isPasted">Traditional 3D measurements no longer offered the right level of performance</h2><p>Ålö Agricultural Machinery (Ningbo) needed a reliable and efficient solution for conducting detailed 3D scanning of its machinery, particularly focusing on the primary machine and mechanical parts. The goal was to analyze the loader’s manufactured parts’ dimensions and deviations.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1697024708409-Picture1-2.webp" style="width: 766px;" class="fr-fic fr-dib"></p><p>The existing measurement methods, manual or using a coordinate measuring machine (CMM), were inadequate and inefficient due to the size of the parts, which could not be moved easily, and the tight tolerances on dimensional accuracy.</p><p>Attempts to use an articulated arm scanner presented other challenges, including on-site vibrations that compromised accuracy too much and the range limitations of the articulated arm. Therefore, operators had to constantly reposition the articulated arm, which negatively impacted the acquisition time. Another factor that bogged down the process was the slow scanning speed, as the arm was limited to only two scan laser lines.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk3MDI0NDYwMzgyLVBpY3R1cmUyLTMud2VicCIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">Creaform’s MetraSCAN 3D is used to assess deformations in Ålö’s agricultural machinery</span></span></span></p><h2 id="isPasted">MetraSCAN 3D scanner: Improved efficiency across the board</h2><p>Creaform stepped in with its <a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan" target="_blank">MetraSCAN &nbsp;3D scanner,</a> coupled with Polyworks software. This solution was demonstrated on-site, scanning a front loader with dimensions of 3 m X 2 m X 1.2 m. The primary application was 3D deviation comparison.</p><p>The scanned data was aligned with the digital theoretical CAD model, and a 3D analysis was performed to generate a deformation colormap. The colour scale was customized to pinpoint major deformations, and some annotations were added at specific critical areas.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk3MDI0NDgyMjQxLVBpY3R1cmUzLndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">Generating a colormap of an agricultural loader</span></span></span></p><p id="isPasted">The MetraSCAN 3D scanner offered a distinct advantage over previous methods. With its 30 blue laser lines and capability to achieve up to 1,800,000 measurements per second, the 3D scanner was fast and portable, making it a great fit for the inspection of large mechanical parts. The scanning process took just 30 minutes, significantly improving inspection times over previous methods.</p><p>With Creaform’s solution, Ålö’ Agricultural Machinery (Ningbo) can now carry out statistical process control (SPC) analyses for the same batch of products all at once, resulting in substantial time and effort savings. These analyses will help the company better control its production methods. Moreover, the MetraSCAN 3D portability and ease of use allow it to be operated anywhere on the site by anyone, offering an efficient and effective solution for the inspection requirements of large mechanical parts.</p>

Ålö Agricultural Machinery (Ningbo) Co., Ltd, a wholly owned subsidiary of Ålö, is a leading manufacturer of loaders and implements for agricultural tractors. With production facilities in four countries and customers in over 50, Ålö holds approximately 30% of the world market for tractor loaders exceeding 50 hp. Since 2020, the company has been part of the JOST Group, a renowned manufacturer of safety-critical systems for commercial vehicles.

New 3D scanners help Alo Agricultural Machinery analyze a loader's part dimensions and deviations

<p id="isPasted">National Steel Car is a leading railroad freight and tank car manufacturer. Based in Hamilton, Ontario, Canada, and founded in 1912, the company develops and produces over 76 model variations of freight and tank cars for railroad, agriculture, chemical, construction, metal, energy, and financial/leasing companies in Canada and the United States.</p><p>Despite their established success, they faced several challenges in order to efficiently achieve the right tolerance levels.</p><h2 id="isPasted"><strong>The challenge: Achieving higher levels of 3D measurement accuracy on complex and large welded parts</strong></h2><p>National Steel Car had a traditional system that allowed design and manufacturing to work with small parts; however, due to the welding process, considerable distortion was often introduced into the large-sized parts.</p><p>This distortion posed a challenge in maintaining tight tolerances. The company had maximized the benefits of their existing system and needed a solution that could handle larger scans and better view distortion to mitigate its impact.</p><p>Jeff Reid, Managing Director of Statistical Engineering at National Steel Car, decided to look for a more advanced 3D measurement solution that would not only offer better accuracy and a large spatial envelope but also one that was robust enough to withstand harsh shop floor environments, including vibrations and high temperatures. “Because our welded parts are hot, they can be difficult to measure,” he explained.</p><h2><strong>The solution:</strong> <strong>MetraSCAN-R BLACK</strong></h2><p>Creaform’s&nbsp;<a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan/technical-specifications" target="_blank">MetraSCAN-R BLACK</a>, a high-end optical and portable CMM scanner engineered to perform highly accurate and repeatable metrology-grade measurements in any condition, caught National Steel Car’s eye.</p><p>The implementation of the MetraSCAN BLACK required a shift in the team’s approach to working with welded parts. Instead of using a laser tracker system, they now had to visualize setups using photogrammetry. Once the team understood the differences, the 3D scanner proved easy to use and highly versatile.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1696506247483-5431-cf-Covered-Hopper-Car-1024x647.webp" style="width: 766px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>The results: Working on large distortions becomes easier</strong></h2><p>The MetraSCAN BLACK significantly improved National Steel Car’s welding fabrication and inspection processes. The tool allowed the company to work on large distortion challenges, which helped create a ‘Lego’ effect: parts fit together more easily, accurately mirroring the models and drawings.</p><p>“MetraSCAN BLACK is a game changer that has dramatically helped us reduce costs and improve throughput in our continuous improvement initiatives,” Jeff said.</p><p>He and his team were particularly satisfied with the support they received during the technology transition, describing the system’s training and the assistance from Creaform’s technical support and training experts as excellent.</p><p>The most significant moment in the process was securing buy-in from the company’s financial group. Nevertheless, after test-driving the MetraSCAN BLACK and observing the unprecedented levels of accuracy and speed, everyone was on board to make the switch.</p><p>Jeff firmly believes that the possibilities are nearly endless with National Steel Car’s new-found 3D scanning solution. He envisions ways in which the MetraSCAN BLACK can be instrumental in potential applications for elevating process capabilities and carrying out more effective problem-solving.</p>

National Steel Car is a leading railroad freight and tank car manufacturer since 1912

National Steel Car is a leading railroad freight and tank car manufacturer. Based in Hamilton, Ontario, Canada, and founded in 1912, the company develops and produces over 76 model variations of freight and tank cars for railroad, agriculture, chemical, construction, metal, energy, and financial/leasing companies in Canada and the United States.

Improving manufacturing precision at National Steel Car with the MetraSCAN BLACK

<p id="isPasted">Creaform has once again teamed up with American Magic, the high-performance sailing franchise, in preparation for the 37<sup>th</sup> America&rsquo;s Cup regatta, which will be held between August and October 2024 in Barcelona, Spain. Leveraging Creaform&rsquo;s HandySCAN and MetraSCAN 3D, the American Magic team is pushing the boundaries of speed and innovation in the bid for the prestigious trophy.</p><h2>What is the American Magic project?</h2><p><a href="https://americanmagic.americascup.com/" target="_blank">American Magic</a> is the US Challenger for the&nbsp;<a href="https://www.americascup.com/" target="_blank">37th America&rsquo;s Cup</a>&mdash;the pinnacle of competitive sailing and the oldest event in international sports. First contested in 1851, the America&rsquo;s Cup predates the modern Olympic Games by 45 years.</p><p>American Magic is proudly representing the New York Yacht Club, which boasts a remarkable record of 25 victories in previous editions, making it the most decorated yacht club in America&rsquo;s Cup history.</p><p>American Magic called upon Creaform to once again become the official 3D Measurement Technologies Supplier for the team&rsquo;s brand-new and highly anticipated AC75, currently being designed to excel in a wide range of sailing conditions and strengthen the NYYC&rsquo;s American Magic&rsquo;s quest for triumph during the race.</p><p>The 37<sup>th</sup> America&rsquo;s Cup includes 5 Challengers from the UK, Switzerland, Italy, France and, of course, the US. There is also 1 Defender (Emirates Team New Zealand, representing the Royal New Zealand Yacht Squadron).</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/gdxkhU-iyM8?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted">Creaform&rsquo;s 3D scanners: Paramount to the Success of the America&rsquo;s Cup</h2><p>We sat down with members of the America&rsquo;s Cup team to learn more about their appreciation of our 3D measurement technologies.</p><p>&ldquo;They are paramount to the success of the 37<sup>th</sup> America&rsquo;s Cup,&rdquo; explained Terry Hutchinson, Skipper and President of Sailing Operations. &ldquo;They are FEA&mdash;fast, efficient and accurate.&rdquo;</p><p>Brandon Linton, Build Manager, explained that the unwavering goal is to produce a yacht as reliable and accurate as possible to the design. The team uses the HandySCAN 3D for reverse engineering on small parts or for components that have no original CAD files.</p><p>On the other hand, they use the MetraSCAN 3D for assessing large parts, such as the vessel&rsquo;s foils, deck and rudder. &ldquo;We are able to quickly acquire full and complete surfaces for future references,&rdquo; he said.</p><p>Global Platform Design Lead, Aaron Perry, added that the HandySCAN 3D will be used until completion of the new American Magic&rsquo;s AC75, while the MetraSCAN 3D is being used early on in the development process to put huge parts together.</p><p>&ldquo;We have such a short time frame; we can&rsquo;t make any mistakes. Thanks to Creaform&rsquo;s technologies, for example, we slashed the time it took to fit a bulkhead from several days to 1 hour,&rdquo; Aaron mentioned. &ldquo;The 3D scanners are invaluable tools to create something so complex and exacting as American Magic. We wouldn&rsquo;t do it any other way.&rdquo;</p><p>This is not the first time Creaform has assisted the NYYC&rsquo;s American Magic. The team used our 3D scanners while designing and building the US Challenger&rsquo;s 75-foot monohull for the 36<sup>th</sup> America&rsquo;s Cup, which took place in March 2021 in New Zealand.</p><p>Creaform is immensely proud to be contributing to the performance of American Magic&rsquo;s race and will be cheering the team on as they hopefully sail to the win! After all, with the America&rsquo;s Cup, there can only be one winner!</p>

The New York City Yacht Club’s American Magic team once again chooses Creaform’s 3D measurement technologies to gear up for the next America’s Cup. Learn more.

American Magic's Team Gears Up for the 37th America's Cup With Creaform

<p>Developing a new type of train that could transport luxury tourists from Tokyo to mountain resorts, such as Hakone and Mount Fuji, and beaches, such as Odawara and Enoshima, in less time. That was the <a href="https://www.odakyu.jp/english/" target="_blank" id="isPasted">Odakyu Electric Railway</a>&rsquo;s mission when the company undertook the design of the Romance Car (ロマンスカー, Romansukā) in 1957. Although its name evokes love and passion, this resort train broke the world&rsquo;s highest speed record of 145 km/h (90 mph) for narrow gauge trains, setting the momentum for the design of the first Shinkansen&mdash;known as the bullet train in English.</p><p id="isPasted">Opening in April 2021, the Romance Car now has its own museum in Ebina City (Kanagawa Prefecture), where visitors can explore the history of the most famous train in Japan after the Shinkansen. A simulator offers an impressive travel experience from the driver&rsquo;s seat, and a diorama recreates the railway connections between Shinjuku and Hakone. While a gallery shows a collection of historical Romance Cars admired throughout the ages, two retired leading Romance Cars and one middle wagon are also on display.</p><p>In this pleasant environment, Anritsu seized the opportunity to convert the first Romance Car into 3D data. Thanks to the <a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d" target="_blank">Go!SCAN SPARK</a>, engineers can now analyze the iconic train to the smallest detail. We invite you to witness this timeless capture with us.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/pPC3qH8LWJQ?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted"><strong>Scan the Entire Romance Car</strong></h2><p>The shape of the first Romance Car was entirely converted into 3D data using the Go!SCAN SPARK. The streamlined front end with mid-mounted circular headlights, the outline of large windows (essential for viewing the passing scenery), the driver&rsquo;s cabin and seat&mdash;everything specific to the emblematic railroad car&mdash;was digitized. From extensive features to intricate details, Anritsu&rsquo;s engineers measured and reproduced the irregularity and distortion of the train&rsquo;s surface.</p><h2><strong>Fast and Easy 3D Data Conversion with the Go!SCAN SPARK</strong></h2><p><strong>&nbsp;</strong>Designed to offer the fastest and easiest 3D experience, the Go!SCAN SPARK can perform up to 1,500,000 measurements per second without specific setup or surface preparation. As seen in the video, the engineers simply pointed and shot!</p><p>The plug-and-play device is so user-friendly that anyone can begin scanning any object (as large as a train compartment) within minutes, without prior experience. The simple user interface offers real-time mesh visualization and quick integration into your preferred CAD software.</p><p><strong>&nbsp;</strong>As shown in the video, the high resolution and level of detail of the Go!SCAN SPARK created spectacular results, simultaneously acquiring color and texture information. Because the Go!SCAN SPARK is easy to handle and light to carry, scanning the entire Romance Car (outside and inside) was effortless.</p><p>Everything about the Go!SCAN SPARK has been considered to make this 3D experience efficient and enjoyable.</p><h2><strong>New Odakyu Railway&rsquo;s Red Romance Car</strong></h2><p>The iconic Romance Car&rsquo;s farewell service occurred on March 8, 1992. Many rail fans swarmed the tracks, taking pictures of the train. This enthusiasm led the Odakyu Electric Railway to unveil the next generation of their famous Romance Car series. The distinctive vermilion exterior of the new Romance Car is indeed a tribute to the original train.</p><p>As expected, the demand for seats in the observation compartments outstrips their availability. The&nbsp;<a href="https://www.odakyu.jp/romancecarmuseum/" target="_blank">Romance Car Museum</a> remains a place for historians and nostalgic fans to observe and celebrate the original icon. And they can rest assured that it will never be lost because the Romance Car has been forever immortalized in 3D data.</p>

Developing a new type of train that could transport luxury tourists from Tokyo to mountain resorts, such as Hakone and Mount Fuji, and beaches, such as Odawara and Enoshima, in less time. That was the Odakyu Electric Railway’s mission when the company undertook the design of the Romance Car in 1957.

Once Fastest Train Now Immortalized to the Finest Detail

<p id="isPasted">Recreating the fusion reaction occurring in the Sun&rsquo;s core here on Earth; this is the mission that scientists and engineers have taken up with&nbsp;<a href="https://www.iter.org/" target="_blank">ITER</a>, one of human history&rsquo;s most ambitious engineering projects.</p><p>ITER, which stands for International Thermonuclear Experimental Reactor, involves the collaboration of 35 nations and consists in manufacturing and operating a massive experimental fusion device called a tokamak. Built of one million components and ten million parts and designed to harness fusion energy, ITER will be the world&rsquo;s largest tokamak ever built, with a plasma radius of 6.2 m and a vacuum vessel of 840 m&sup3; able to withstand temperatures reaching 150 million degrees Celsius, nothing less.</p><p>ITER&rsquo;s objective is to demonstrate the feasibility and cost-effectiveness of nuclear fusion as a source of large-scale, carbon-free energy. To this intent, the ITER project&rsquo;s tokamak is designed to generate 500 MW of fusion power from 50 MW of input heating power, reaching a ten-fold return on power (Q=10).</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693482337569-Tokamak-maqueta-completa-ITER-1.webp" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">The Cantabrian company&nbsp;<a href="https://www.ensa.es/?lang=en" target="_blank">Equipos Nucleares, S.A. (ENSA)</a> has been tasked to design and build components for the tokamak&rsquo;s toroidal vacuum vessel. The project will be housed in thirty-nine buildings and technical areas under construction on a 180-hectare site in Cadarache, southern France. The heart of the facility&mdash;the Tokamak Building&mdash;is an impressive seven-story structure in reinforced concrete. As the buildings are structurally completed, equipment can be installed and assembled.</p><p>Beyond any doubt, controlling the dimensions of a 23,000-ton, 28m-diameter tokamak during the assembly process mandatary requires highly accurate 3-dimensional measuring equipment to ensure that the exact tolerances for machine operation are achieved.</p><p>This is where the contribution of AsorCAD takes its full value.</p><h2 id="isPasted"><strong>The right partner for exact dimensions<br></strong></h2><p>Over the last 25 years, the Spain-based engineering company&nbsp;<u>AsorCAD</u> has been known for its sharp specialization in 3D technology. For this reason, ENSA asked AsorCAD to take charge of the 3D scanning, reverse engineering, and metrology work to construct the ITER project&rsquo;s nuclear fusion reactor.</p><p>Since early 2015, ENSA benefits from AsorCAD&rsquo;s expertise. Together, they were able to scan the lateral edges of the nine sectors of the tokamak&rsquo;s plasma chamber, also called the torus. This was an essential task because, since each sector is manufactured separately, it requires designing joining pieces to connect the different sections and ensure they meet up perfectly once assembled.</p><h2><strong>Precise 3D measurements for perfect fitting</strong></h2><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693482358732-Tokamak-escaneado-3-1024x768.webp" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">To ensure a perfect fitting of the different sections of the torus, AsorCAD used the Creaform <a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan" target="_blank">MetraSCAN 3D scanner</a> for the toroidal components and the <a href="https://www.creaform3d.com/en/metrology-solutions/optical-measuring-systems-maxshot-3d" target="_blank">MaxSHOT 3D photogrammetry system</a> for the large-scale parts. Then, some measurements were verified with the <a href="https://www.creaform3d.com/en/metrology-solutions/coordinate-measuring-machines-handyprobe" target="_blank">HandyPROBE CMM</a>, also manufactured by Creaform.</p><p>Because they are free from any rigid setup requirements, this 3D measuring equipment is portable and highly reliable for on-site work. Their measurement accuracy is insensitive to the instabilities of the environment, which means that they are not affected by movement, vibrations, or changes in temperature or lighting conditions. These qualities enabled AsorCAD to perform highly accurate 3D scanning and measurements at the ENSA facilities without the need to transport enormous equipment.</p><p>Once 3D scans of the lateral edges of each torus sector were accurately captured, AsorCAD used&nbsp;<a href="https://oqton.com/geomagic-designx/" target="_blank">Geomagic Design X software</a> to create their corresponding CAD models.</p><p>Then, by reverse engineering, ENSA could design connecting elements with exact dimensions to join the different existing sections. AsorCAD used the MetraSCAN 3D scanner again to scan all these manufactured joining pieces for final inspection and approbation.<strong>&nbsp;</strong><strong>&nbsp;</strong></p><h2><strong>On the way to carbon-free energy<br></strong></h2><p>Assembly work of the tokamak&rsquo;s toroidal vacuum vessel has now started in Cadarache. The first plasma tests are expected by 2025. Afterwards, the ITER project will continue until it reaches its objective, which is producing a ten-times return on energy injected in the plasma (Q=10) to demonstrate nuclear fusion&rsquo;s viability as a sustainable, non-carbon-emitting global energy supply. Until then, the ITER project can continue to rely on its valuable partners and advisors, such as AsorCAD and Creaform.</p><p><br></p>

Recreating the fusion reaction occurring in the Sun’s core here on Earth; this is the mission that scientists and engineers have taken up with ITER, one of human history’s most ambitious engineering projects.

Harnessing the Power of Fusion Energy, a Dream Becoming Reality

<p id="isPasted">More time&mdash;this is a luxury that many people wish they could afford. What about engineers who work long hours to design and manufacture molds to produce automotive performance parts, such as engine devices, transmissions, and electronic controls? What would they do if they could save 85% of the time required for mold inspections?</p><p>The possibilities are numerous, but chances are high that they would opt to inspect more molds or proceed with more in-depth inspections on each mold. They could also recover this valuable time and invest it in innovation, such as in the development of new processes and new products or in the improvement of their existing techniques.</p><p>Sound too good to be true? It&rsquo;s not; it&rsquo;s just a question of challenging the status quo and measuring the performance of the existing equipment used for inspection against another technology that is more innovative and more efficient. That&rsquo;s exactly what engineers working for an important company in the automotive mold industry did. They compared a renowned blue light 3D scanner to the Creaform HandySCAN 3D|BLACK Elite.</p><p>The time difference to perform the same scanning process was light years apart in terms of inspection time&mdash;i.e., 294 minutes with the blue light 3D scanner versus 45 minutes with the HandySCAN 3D|BLACK Elite.</p><ul><li>How can this significant time gap be explained?</li><li>How did the HandySCAN 3D|BLACK Elite work so fast?</li><li>What interfered with the blue light 3D scanner?</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692200967674-Industrial-press-for-sheet-metal-stamping-for-automotive-1024x738.jpeg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">Detail of Industrial press for sheet metal stamping</span></span></span></p><p>In this blog post, we will explain the process the engineers followed and the results that they obtained. It shows the performance of the portable laser-based 3D scanner compared with the blue light-based 3D scanner, and the data is unequivocal. It reveals that the handheld device has a significantly faster scanning process while obtaining the same level of accuracy as its tripod-mounted companion.</p><h2 id="isPasted"><strong>Benchmarking Data<a href="https://www.creaform3d.com/blog/results-revealed-and-facts-exposed-benchmarking-two-3d-scanning-metrology-solutions-to-save-inspection-time/#_ftn1" name="_ftnref1" target="_blank"><sup>1</sup></a></strong></h2><p>The benchmark occurred on the factory production floor. The engineers placed the mold on the shop floor overnight to reach thermal equilibrium so that they could get a fair comparison between the HandySCAN 3D | BLACK Elite and their existing measuring system. The mold dimensions used for the benchmark were roughly 800 mm x 1000 mm x 1000 mm (31.5 x 39.5 x 39.5 in). The part was composed of tubes and electromechanical components, which made the design relatively complex, including some hidden areas that are difficult to capture with measuring equipment. Finally, the material was moderately shiny, which required a powder application in the case of the blue light 3D scanner.</p><table><tbody><tr><td><strong>&nbsp;Part Size</strong></td><td>&nbsp;800 mm x 1000 mm x 1000 mm<br>(31.5 x 39.5 x 39.5 in)</td></tr><tr><td><strong>&nbsp;Design Complexity</strong></td><td>&nbsp;Complex with tubes and electromechanical components attached</td></tr><tr><td><strong>&nbsp;Surface Reflectivity</strong></td><td>&nbsp;Shiny</td></tr><tr><td><strong>&nbsp;Measurement Environment<br></strong></td><td>&nbsp;Shop Floor<br></td></tr></tbody></table><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692201009485-high-precision-mold-and-die-manufacture-for-automotive-1024x841.jpeg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">high precision mold and die manufacture for automotive and aero space, high accuracy cutting part for casting mold of die casting and low pressure casting, finishing machining of mold and die</span></span></span></p><h3 id="isPasted"><strong>Scanning Process</strong></h3><ol><li><strong>Setup and Part Preparation</strong>: For both measuring instruments, engineers started by applying approximately 40 positioning targets on the surface of the mold. In the case of the HandySCAN 3D|BLACK Elite, they plugged in the device. In the case of the blue light 3D scanner, they installed the tripod and mounted the scanner on it. Due to the mold&rsquo;s shiny surface, they also had to apply powder on the part&mdash;a step that was not required with the HandySCAN 3D|BLACK Elite.</li></ol><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692201062504-Blue-light-optical-3D-measuring-systems.webp" style="width: 766px;" class="fr-fic fr-dib"></p><ol><li id="isPasted"><strong>Scan and Post Processing</strong>: Then, engineers proceeded with the scan by collecting measurements and acquiring data. With the laser-based system, they simply had to wave the HandySCAN 3D | BLACK Elite over the mold, as if they were scattering spray paint. With the light-based system, they had to move the tripod at different positions and angles and add extra pieces of cardboard to avoid external interference. Following these steps, engineers could process the scan data and get a clean STL file.</li><li><strong>Part Cleaning</strong>: Finally, engineers completed their inspection by removing the positioning targets. With the blue light 3D scanner, they also had to clean out the powder from the surface of the mold.</li></ol><h3 id="isPasted"><strong>Inspection Time</strong></h3><p>The total inspection time required to set up, prepare, scan, process, and clean the mold took 45 minutes with the laser-based, handheld, portable 3D scanner compared to 294 minutes with the blue light 3D scanner.</p><table><thead><tr><th>Steps</th><th>&nbsp;HandySCAN 3D|BLACK Elite</th><th>&nbsp;Blue Light 3D Scanner</th><th>&nbsp;More time needed with the Blue Light 3D Scanner</th></tr></thead><tbody><tr><td>&nbsp;Setup and Part Preparation</td><td>5</td><td>84</td><td>16.8x</td></tr><tr><td>&nbsp;Scan and Post-Processing</td><td>30</td><td>180</td><td>6x</td></tr><tr><td>&nbsp;Part Cleaning (after scanning)</td><td>10</td><td>30</td><td>3x</td></tr><tr><td><strong>TIME (minutes)</strong></td><td><strong>45</strong></td><td><strong>294</strong></td><td><strong>6.5x</strong></td></tr></tbody></table><p>In short, when compared with the Creaform HandySCAN 3D | BLACK Elite, the renowned blue light 3D scanner required 6.5x more time to inspect the same mold under the same environmental conditions and with equivalent accuracy.</p><h2><strong>The Stark Time Difference Explained</strong></h2><h3>Expeditious Speed from Setup to Scan</h3><p>Unlike the handheld HandySCAN 3D|BLACK Elite, the blue light 3D scanner had to be mounted on a tripod and placed at the right position and angle prior to activating the camera. Consequently, multiple adjustments were needed.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692201093570-Optical-blue-light-3D-scanner-1024x683.jpeg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">Industrial Optical 3D scanner</span></span></span></p><p id="isPasted">Because each mold has a unique shape with its own geometry and specific features, engineers must define the right combination of angles and positions to capture the entire profile of the mold. Based on their current internal procedure, the tripod had to be moved to 16 different positions in order to fully scan the part. First, engineers placed the tripod in 10 different locations around the mold with the camera positioned at 45&deg;. Then, they moved it to 6 additional positions, this time oriented at 85&deg;. Between each manipulation of the tripod, 4 distinct and precise steps had to be performed to properly change the camera angle and position.</p><p>These laborious manipulations largely explain why the preparation and scanning sessions were more time-consuming with the blue light 3D scanner.</p><h3>Slick Ergonomics and Light Portability</h3><p>Because the structured light metrology system mounted on a tripod had to rotate 360&deg; around the mold to fully scan its shape, engineers had to allocate enough space on the shop floor to accommodate both the mold and the light-based 3D scanner.</p><p>Engineers noted that the light-based system had to be positioned in the exact location to capture hidden features effectively. Repositioning the camera at the right angle involved a lot of trial and error, which was tedious and, again, time-consuming. In contrast, restricted areas were easier to scan with the HandySCAN 3D | BLACK Elite. Engineers could easily orientate the optics at the right angle to acquire the mold&rsquo;s complex geometry since they were holding the device in their hand and could see the data capture live. If details were lacking, they knew right away and could browse the 3D laser scanner back over the specific area to easily capture the missing data, saving precious time during the scanning process.</p><h3>Versatility on any Surface Finish</h3><p>As previously mentioned, the mold&rsquo;s reflective surface had to be coated with powder spray prior to using the blue light technology. Consequently, extra time was also required to remove all of the powder coating at the end of the inspection. In contrast, because the laser scanning technology could scan any type of material finish without surface preparation, the setup and part preparation took almost 17x less time with the versatile HandySCAN 3D|BLACK Elite.</p><h3>Shop-Floor Accuracy and Reliability</h3><p>In order to avoid external interference and reflectivity that could have affected the performance of the light-based 3D scanner, engineers surrounded the mold with pieces of cardboard. This way, they were assured that light and the surrounding environment would not impact the measurement results. This precaution was not necessary with the laser-based 3D scanner, which also contributed to shortening the scanning process.</p><h2><strong>Brilliant HandySCAN 3D|BLACK Elite</strong></h2><p><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692201119565-HandySCAN-BLACK-Elite_Angle_Front_Left-232x300.webp" style="width: 300px;" class="fr-fic fr-dib"></strong><br></p><p id="isPasted">The HandySCAN 3D|BLACK Elite outshone the renowned blue light 3D scanner in every way for this benchmark. Not only was 85% of the inspection time saved and invested in more in-depth inspections, but also the mold inspection was easier and simpler, regardless of the environmental instability, material reflectivity, or engineers&rsquo; level of expertise in 3D scanning.</p><p>The engineers summarized their experience with the Creaform HandySCAN 3D|BLACK Elite as follows:</p><ol><li>Portability made the inspection straightforward: the measuring system was brought to the part, not the other way around.</li><li>Part preparation was minimal: simply place targets, plug in the device, and you are ready to scan.</li><li>Blue laser performance on highly reflective surfaces was impressive.</li><li>Scanning motion was intuitive and easily comprehensible, even for beginners.</li><li>Real-time visualization helped users identify and patch any missed areas while scanning.</li><li>Minimal cleanup was required after the inspection.</li></ol><p>HandySCAN 3D|BLACK Elite&rsquo;s distinct benefits of speed, portability, versatility, and accuracy were clearly demonstrated, which resulted in a successful experience and led to the replacement of the existing blue light scanning system.</p><hr><p><a href="https://www.creaform3d.com/blog/results-revealed-and-facts-exposed-benchmarking-two-3d-scanning-metrology-solutions-to-save-inspection-time/#_ftnref1" name="_ftn1" target="_blank">[1]</a> For this benchmark, both the blue light and laser 3D scanning technologies were equivalent in accuracy (25&micro;m).</p>

More time—this is a luxury that many people wish they could afford. What about engineers who work long hours to design and manufacture molds to produce automotive performance parts, such as engine devices, transmissions, and electronic controls? What would they do if they could save 85% of the time required for mold inspections?

Results Revealed and Facts Exposed: Benchmarking Two 3D Scanning Metrology Solutions to Save Inspection Time

<p id="isPasted"><a href="https://www.aicenter.eu/" target="_blank">AIC-Automotive Intelligence Center</a>, based in Amorebieta-Etxano, Bizkaia, is a European center for the generation of value for the automotive industry based on a concept of open innovation where companies improve their positioning through cooperation. Using a market approach, AIC offers services that improve the capacity of the automotive industry globally, integrating training, research, industrial development, and new businesses under a single structure. Its facilities are currently home to 30 organizations from nine different nationalities, and over 950 professionals.</p><p>All of their projects are part of a training program known as the <a href="https://www.aicenter.eu/activity/program/extreme-automotive-program/" target="_blank">Extreme Automotive Program (EAP)</a>, in which future professionals are trained by carrying out real projects in a company scenario. For AIC, it is important that they acquire skills in digitalization, quality control and component analysis.</p><h2 id="isPasted"><strong>Using 3D scanners for training</strong></h2><p>In the training program for automotive industry professionals, AIC teaches trainees how to make CAD designs of components. For this purpose, it is very important to have a measuring system that enables reverse engineering and measurement of parts.</p><p>It was essential for this system to be able to digitize individual components as well as a complete car, due to the platform vehicle in which to incorporate the new designed parts.</p><p><a href="https://www.creaform3d.com/en/metrology-solutions/creaform-product-overview" target="_blank">Creaform&rsquo;s measurement technologies</a> were convincing, as they could perform accurate scans very fast, and the scanned file could be post-processed to obtain CADs of the parts. It also allowed for the production of color maps and reports of how the parts compared to the original CAD.</p><p>&ldquo;In order to incorporate Creaform&rsquo;s measurement solution into our projects, several professionals from the group were trained in the use and calibration of the equipment, as well as the software. In this way, we were able to carry out several projects at the same time, each working autonomously. We also gave internal training to the new people so that they can use this tool in their projects,&rdquo; says Hector Martinez, Extreme Automotive Program Tutor at AIC.</p><h3><strong>Project 1: Manufacture of a windshield for</strong></h3><p><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691668605738-2023-07-28-10_07_25-2023_07_Case-Study-AIC_final_EN_rev.docx-Word-1024x387.webp" style="width: 766px;" class="fr-fic fr-dib"></strong></p><p id="isPasted">As part of the ObenCar training program, a vehicle platform was designed, and a bespoke windshield manufactured. In order to make the design, the chassis structure of the vehicle was digitized using MetraSCAN 3D. With the dimensions obtained, the CAD design was generated. The chassis structure consisted mainly of welded tubes, so it was easy to process the measurement to obtain the geometries of the tubes. Then, a structure was designed to support the windshield, consisting of additively manufactured metal parts, together with curved profiles. All of this was screwed to the tubes of the ObenCar chassis. Finally, once the windshield structure was installed, we used the measuring equipment to check the assembly deviations, with respect to accuracy, before the final installation of the windshield.</p><h3><strong>Project 2: Design and installation of a sunroof</strong></h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691668639487-techo-1024x658.webp" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">Another project carried out on the ObenCar vehicle was the design and installation of a sunroof. To obtain the dimensions of the chassis, the chassis tubes were digitized. These results were used to measure the sunroof in order to make the structural parts used to fix the sunroof to the chassis.</p><h2><strong>Advantages of the MetraSCAN 3D</strong></h2><p>The main&nbsp;<a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan" target="_blank">advantages of the MetraSCAN 3D</a> are undoubtedly the time saved and the accuracy of the results obtained. The 3D scanner can scan an area or part required for assembly or manufacture within an accuracy of 0.025 mm; it makes measurement easy and facilitates decision-making. After such accurate, easy, and fast scanning, all that remains is to process the data in the software and choose which component of the part needs to be exported and in which format. Finally, it is also very helpful to visualize parts in CAD without having to draw them from scratch.</p><p>&ldquo;It would not have been possible to carry out that many projects without the Creaform tool, as it has enabled us to obtain the necessary information together with a high level of accuracy. We are working on more component projects to add to the ObenCar vehicle. We also often reverse engineer existing parts, from which we need to obtain the CAD file. Creaform&rsquo;s 3D tools will be very helpful for the design and improvement of parts. We also enjoyed working with Creaform&rsquo;s staff, as they provided us with solutions when we needed their help,&rdquo; says Hector Martinez.</p>

AIC-Automotive Intelligence Center, based in Amorebieta-Etxano, Bizkaia, is a European center for the generation of value for the automotive industry based on a concept of open innovation where companies improve their positioning through cooperation.

Automotive Intelligence Center: 3D scanners - a key aid when training for a career in the automotive industry

<p>One of Apex Race Parts&rsquo; lines of business is designing chassis-optimized wheels for all types of vehicle brands, like Aston Martin, Audi, BMW, Honda, Ford, Porsche and Tesla. David Liu, Engineering Project Manager at APEX Race Sports, explained the inherent challenges regarding development: &ldquo;<em id="isPasted">Our primary issue was the lack of documentation regarding OEM brake components. While aftermarket brake system manufacturers will generally provide technical information which allows for well-optimized designs, carmakers do not divulge information for their factory components, which means this data had to be gathered by tedious manual measurements.</em>&rdquo;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691056444642-tesla-3d-scanning-handyscan-3d-scaled.webp" style="width: 766px;" class="fr-fic fr-dib"></p><p>As David pointed out, manual measurements were much more time-consuming and provided less complete data. The APEX Race Parts team decided to look for an alternative method to accelerate the process of acquiring <a href="https://www.creaform3d.com/en/metrology-solutions/creaform-product-overview" target="_blank" id="isPasted">3D measurements</a>. And that method involved 3D scanners.</p><h2 id="isPasted"><strong>3D scanners: A proven track record in the automotive industry</strong></h2><p>For years, companies in the auto industry have been leveraging 3D scanners for&nbsp;<a href="https://www.creaform3d.com/en/applications" target="_blank">many different applications</a>, including design, quality control, reverse engineering, tuning, and retrofitting.</p><p>&ldquo;<em>We were looking for a handheld solution that was highly accurate</em>,&rdquo; David said. &ldquo;<em>As we often are working with cars &ldquo;in the field&rdquo; at racetracks or garages, it was imperative that we find a solution that depended on a minimum amount of existing infrastructure. The physical size was also a concern, as we often scan components with limited mobility and clearance, such as in the wheel well of a car.</em>&rdquo;</p><p>That&rsquo;s when the team started trialing several 3D scanners on the market to test-drive how they stacked up to the requirements with outsourced services.</p><h2><strong>APEX Race Parts choose Creaform 3D scanners</strong></h2><p>APEX Race Parts settled on Creaform&rsquo;s HandySCAN 3D from the SILVER Series after observing favorable results with the scans. The team greatly appreciated the scanner&rsquo;s compact size and ease of use when 3D scanning in the field as well as how seamless the integrated 3D scanning software could work with APEX Race Parts&rsquo; existing software solutions.</p><p>&ldquo;<em>With the training provided by Creaform and its partners, we were able to implement the 3D measurement workflow as part of our standard data collection process very quickly,</em>&rdquo; David added.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691056476237-vxelements-3d-data-acquisition-platform-scan-apex-race-parts-1024x576.webp" style="width: 766px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>APEX Race Parts&rsquo; aha! moment with 3D scanning</strong></h2><p>According to David, making a spur-of-the-moment decision during the test fit of a sample wheel to scan a particular car was eye-opening for the team. Previously, it would have been necessary to block out significantly more time to measure components manually or to arrange 3D imaging with an outside supplier&mdash;both of which would have taken much longer with no guarantees of availability.</p><p>The ability to set up the 3D scanner and almost instantly gather data allowed the business&rsquo; experts to enjoy more flexibility in the number of cars selected for data collection.</p><h2><strong>Immediate gains in efficiency and inspection integrity thanks to 3D scanners</strong></h2><p>The APEX Race Parts pros were impressed with the net effects of using&nbsp;<a href="https://www.creaform3d.com/en/portable-3d-scanners" target="_blank">Creaform 3D scanners</a> versus manual measuring&mdash;starting with time savings.</p><p>&ldquo;<em>3D measurements provide the ability to gather a huge amount of information very quickly. The ability to accurately replicate all of a vehicle&rsquo;s suspension components is useful in identifying potential conflict points that may not have been detected in a visual inspection</em>,&rdquo; said David.</p><p>&ldquo;<em>The incremental cost of data collection has been reduced, which allows APEX to optimize application-specific wheels with tighter margins. This leads to lighter, stronger, and more aesthetically pleasing wheel designs</em>.&rdquo;</p><p>In addition to elevating APEX Race Cars&rsquo; engineering and R&amp;D processes, Creaform&rsquo;s 3D scanning technology has allowed it to put out supplementary educational material, which has been well-received by the car racing community.</p><p>&ldquo;<em>APEX has always acted as an educator and a trustworthy repository of information for the various communities we serve. The additional data collection made possible by Creaform&rsquo;s technologies has allowed us to respond more quickly and with more in-depth analyses,</em>&rdquo; David pointed out.</p>

Based in California but servicing the entire United States, APEX Race Parts brings the latest wheel and tire technology to the automotive racing industry. The business employs dozens of car racing experts that are driven by the need for speed and performance.

APEX Race Parts uses 3D scanner to stay at the wheel of impressive race car innovation

<p id="isPasted">Based in Boppard, Germany, <a href="https://www.bomag.com/" target="_blank">BOMAG</a> is a global manufacturer of construction machinery and a technology partner in road construction and earthwork operations. In addition to its main focus on soil and asphalt rollers, milling machines and road finishers, and manually controlled compaction technology, the company also offers a complete portfolio of stabilizers, recyclers and machines for waste compaction. Through its equipment and digitalization solutions, BOMAG facilitates the efficient and responsible expansion of road and traffic infrastructure. Founded in 1957, the company now employs more than 2,500 people.</p><p>BOMAG is an innovative company that is committed to research and development as well as production modernization. The construction equipment manufacturer has been using metrology technology with measuring devices and measuring arms for years. Recently, BOMAG&rsquo;s team was searching for 3D measurement solutions to add to its portfolio that would enable uncomplicated, flexible and non-contact measurement of free-form surfaces, such as castings and plastic parts. The ideal 3D measurement solution also needed to be portable so that scanning of large components and the highest quality standards could be guaranteed.</p><p>With its <a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan" target="_blank">MetraSCAN BLACK|Elite</a> and <a href="https://www.creaform3d.com/en/metrology-solutions/coordinate-measuring-machines-handyprobe" target="_blank">HandyPROBE</a>, Creaform offers a range of solutions that not only meet quality requirements but also flexibility, speed, high accuracy and intuitive. This led BOMAG to select Creaform&rsquo;s technologies to revamp its workflows.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1690447567140-Pic2_Bomag_20230331_120605_resized.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">MetraSCAN 3D and HandyPROBE impress with their intuitive usability. &ndash; Source: BOMAG GmbH</span></span></span></p><p id="isPasted">The scanner with PolyWorks Inspector software is currently used mainly for inspecting in incoming goods. The HandyPROBE has been used successfully in setting up large jigs for welding projects.</p><p>Another advantage is that through reverse engineering, data can now be used more efficiently and extensively. Thanks to the metrology equipment, the data obtained is now immediately available for analysis in digital form.</p><p>Reverse engineering also means that potential optimizations can be determined with precision and passed on directly to the right teams. This translates into a streamlined coordination process with external suppliers&mdash;all while simplifying the transfer of measurement methodology and requests for test reports and plans.</p><p>When castings are transferred between suppliers, complete measurements are taken by the quality department with the MetraSCAN 3D and HandyPROBE to develop comprehensive technical documentation. In addition, components for which no original data or CAD models were available can now be recreated through reverse engineering with Creaform 3D scanning solutions and Siemens NX; technical drawings for production can be derived from these.</p><p>Mobility, flexibility and accuracy are particularly important aspects in large components. Thanks to the large measuring radius of the MetraSCAN 3D, the entire component can be measured with precision. Bernd Braun, Quality Manager Machining, said: &ldquo;The MetraSCAN BLACK|Elite opens up far-reaching possibilities for us when it comes to measuring large parts. Creaform solutions are perfectly aligned with our vision to use innovative solutions as part of our process optimization projects.&rdquo;</p>

The accuracy, mobility and flexibility of Creaform metrology equipment make it particularly suitable for measuring large components. – Source: BOMAG GmbH

BOMAG’s team was searching for 3D measurement solutions to add to its portfolio that would enable uncomplicated, flexible and non-contact measurement of free-form surfaces, such as castings and plastic parts. The ideal 3D measurement solution also needed to be portable so that scanning of large components and the highest quality standards could be guaranteed.

3D scanners: New possibilities for measuring large parts

<p><strong>The path to building perfect parts can be hazardous. Manufacturing defects can arise at any time in the manufacturing process, even if the mold, dye, or jig is engineered according to the CAD model. Some phenomena can interfere with the tooling, causing problems and imperfections on the parts. Consequently, the produced parts do not correspond to the technical requirements. Adjustments and iterations are required to ensure that the tools and molds, even if they correspond to their nominal models, produce parts that meet inspection standards and customer demands. Quality control (QC) must achieve this while minimizing inspection time and the production costs associated with rejected parts.&nbsp;</strong></p><p>This blog aims to illustrate the different manufacturing challenges leading to product defects and highlight how 3D scanning technology allows for more features and parts to be inspected. It also describes how QC managers can shorten inspection time and reduce production costs associated with scraps. The objective is, of course, to improve the <a href="https://www.creaform3d.com/blog/how-to-make-sure-that-tools-and-molds-build-perfect-parts/" id="isPasted" target="_blank">detection of manufacturing defects and produce parts of better quality</a>&mdash;according to specifications and within tolerances.&nbsp;</p><h2 id="isPasted"><strong>The Most Common Causes of Product Defects<br></strong></h2><p>The reality of an industrial environment differs from the theory illustrated in CAD models. Multiple unforeseeable phenomena come into play when producing parts. Because metal fusion is a complex phenomenon, the manufacturing process does not follow a linear and repeatable path <a href="https://www.creaform3d.com/blog/using-3d-scanning-to-improve-the-quality-of-sheet-metal-molds/" target="_blank">from the mold to the final part</a>. Spring backs when stamping a dye, shrinkage when building a mold made of composite material, or thermal forces when welding two elements together are other good examples of unpredictable phenomena that can impact tooling precision. Difficult to control, these phenomena make it impossible to predict the final result before getting the parts in hand.</p><p>Initially, the tooling is built according to the theoretical model, which is developed to create manufactured parts that meet the technical requirements. But, in the reality of the industry, the phenomena above interfere with the molded or stamped parts. As a result, the parts do not meet the technical requirements and must be adjusted, corrected, and altered to pass the quality controls.</p><h3><strong>Defect Classification</strong></h3><p>We can classify defects into four main categories:</p><ol><li>Manufacturing defects (part not conforming to requirements)</li><li>Assembly defects (part not assembled correctly)</li><li>Defects related to the raw material (ex: wrong type of steel that causes more or less spring back, poor surface finish, etc.)</li><li>Defects related to the general wear of parts or components (ex: mold that crumbles)</li></ol><p>Several causes are possible in each of these categories. Human error is undoubtedly the most current.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689852400047-mold-inspection-handyscan-3d-scanner-XingDongFang-1024x768.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">A quality control metrologist scans a mold with the HandySCAN 3D directly on the shop floor&nbsp;</span></span></span></p><h2 id="isPasted"><strong>The Best Method to Detect Product Defects<br></strong></h2><p>When unpredictable phenomena alter manufactured parts, an iterative quality control process starts. The best method is to work on the part before adjusting the tooling. More precisely, this method involves producing a part, measuring it with quality control equipment and <a href="https://www.creaform3d.com/en/metrology-solutions/vxinspect-dimensional-inspection-software-module" target="_blank">inspection software</a>, and analyzing deviations between the part and the CAD model. Hence, if we notice some missing (or extra) mms in one place, we will go to the corresponding surface on the mold, dye, or jig to grind or add material. The iteration is thus performed on the tooling after measuring the manufactured part.</p><p>Once this operation is completed, we restart the manufacturing process to produce a new part that will be measured again to verify any remaining deviations. This iterative process will continue on a loop until we obtain the desired part (i.e., when the manufactured part corresponds to its CAD model).</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689852425768-bath-colormap-vxinspect-vxelements-1024x542.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">Defects characterization of a bath in VXinspect module: Creaform&rsquo;s Inspection Software&nbsp;</span></span></span></p><h2 id="isPasted"><strong>The Best Solution to Build Parts with Fewer Defects<br></strong></h2><p>This iterative quality control process requires fast measurement equipment that promptly supplies the complete dimensional information to produce the next part without delay. The measuring tool must also be portable to measure parts directly on the shop floor. This way, parts no longer have to be brought to the coordinate measuring machine (CMM), saving precious time and allowing for more inspections. The measuring instrument should also be easy to use, with a digital Go/No-Go feature that lets operators quickly evaluate dimensional measurements and easily identify parts that do not meet the required tolerances. Finally, it should offer the capacity to measure all types of sizes, surface finishes, and geometries without surface preparation.</p><p><a href="https://www.creaform3d.com/en/portable-3d-scanners" target="_blank">3D scanning technology</a>, with its speed, portability, and versatility, meets these requirements, allowing production and quality teams to inspect parts and detect defects&mdash;particularly those in the first and second categories. In fact, 3D scanners help reduce human impact in manufacturing processes by reducing visual inspections or the use of manual tools. They are also helpful in measuring the wear of parts, i.e., to know when it is the right time to replace a tool or a mold.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689852450314-sheet-metal-quality-control-metrascan-3d-scanner_hong-xu-1024x768.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">A metrologist is performing a scan of a sheet metal on jigs with the MetraSCAN 3D scanner combined with the C-Track optical Tracker&nbsp;</span></span></span></p><h2 id="isPasted"><strong>The Benefits of 3D Scanning: Better Part Quality with Optimized Inspection Time</strong></h2><h3><strong>More Effective Inspection</strong></h3><p>When quality control detects manufacturing defects (i.e., when manufactured parts do not match technical requirements), the company falls into an investigation mode, which can cause stress and uncertainty. But with 3D scanning, the quality team can now intervene without further delays and find the root cause by quickly acquiring a lot of data and investigating directly on the shop floor.</p><h3><strong>More Parts and Features Inspected</strong></h3><p>Because 3D scanning technology is faster and acquires more data than the CMM, it can measure more parts or inspect more features with more detailed information. This way, managers can make better decisions to optimize manufacturing processes. In addition, by measuring parts directly on the production floor without bringing them to the metrology lab, the quality team saves time that can be recovered to inspect even more parts.</p><h3><strong>Optimized Iteration Process with Reverse Engineering</strong></h3><p>Once certified tooling produces manufactured parts according to technical requirements, the mold, dye, or jig can be scanned for <a href="https://www.creaform3d.com/blog/how-to-get-started-with-product-reverse-engineering/" target="_blank">reverse engineering</a>. Thus, if the tooling wears out and a new one is required, we will not use the nominal model for the next manufacturing process. Instead, we can work directly from the model that builds parts within inspection standards. This way, the initial iteration process is optimized for future productions.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689852473374-vxmodel-entities-mold-reverse-engineering-1024x576.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">The reverse engineering of a mold was facilitated by employing entities generated using VXmodel.&nbsp;</span></span></span></p><h2 id="isPasted"><strong>Product Defects are Unavoidable, Even for the Best Manufacturers<br></strong></h2><p>Unpredictable phenomena can occur at any time during manufacturing. Because these phenomena can cause unexpected spring backs or shrinkage, adjustments are necessary to ensure that the tooling, even if it matches its nominal model, produces good parts that meet customer demands. Consequently, quality teams must have the right measuring equipment to detect and correct defects quickly.</p><p>3D scanning facilitates these required iterations. Due to its speed, portability, and versatility, it is an effective alternative to the CMM that can remain free for critical and final inspections. In addition, 3D scanning offers the possibility of reverse engineering the tooling that produces the good parts, performing more quality controls, and quickly correcting unexpected issues that may occur at any time.</p><p>In short, 3D scanning equipment provides the manufacturing industry with more information and enables quality inspectors to measure more parts and features faster. 3D scanners not only help to free up CMM time but also guarantee to minimize inspection time and production costs, resulting in parts of better quality.</p>

This blog aims to illustrate the different manufacturing challenges leading to product defects and highlight how 3D scanning technology allows for more features and parts to be inspected. It also describes how QC managers can shorten inspection time and reduce production costs associated with scraps.

How to better detect manufacturing defects

<p id="isPasted">From the smallest mechanical components to the tiniest adjustments in its driving technique, <a href="https://waynetaylorracing.com/" target="_blank">Wayne Taylor Racing with Andretti Autosport (WTRAndretti)</a> is always looking for ways to improve and gain an edge over the competition. The team is competing in the GTP and GTD Classes for the <a href="https://www.imsa.com/weathertech/" target="_blank">IMSA WeatherTech SportsCar Championship,</a> which features the fastest and most technologically advanced cars in North America, as well as in the <a href="https://www.lamborghini.com/en-en/motorsport/super-trofeo/north-america" target="_blank">North American Lamborghini Super Trofeo Series</a>. They need to rely on partners and equipment they can trust.</p><p>Whether to improve the car&rsquo;s aerodynamics or make the driver&rsquo;s experience more comfortable in the cockpit, WTRAndretti&rsquo;s engineers decided to trust and rely on <a href="https://www.creaform3d.com/en/metrology-solutions" target="_blank">Creaform&rsquo;s expertise and technology</a>. With the capability to precisely digitize all newly designed parts, they are certain that everything will fit together perfectly and function as intended.</p><p>See WTRAndretti&rsquo;s engineers and drivers in action on the race track.</p><p><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe width="640" height="360" src="https://www.youtube.com/embed/zGAPmWtdSlo?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted"><strong>3D Scanning Helps Put Every Piece at Its Place</strong></h2><p>No doubt, in these intense and exhilarating races, engineers and drivers must orchestrate strategies, settings, designs, and new components in flawless harmony to maintain their speed and stay ahead of the competition. Each piece needs to be placed perfectly every time. To do so, scanning the whole car before and after a race allows them to understand how it has behaved during the event and plan accordingly for the next races.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689243048299-wtr-racing-car-3dscanning-metrascan-3d.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">WTRAndretti engineer scanning a special part with the Creaform MetraSCAN 3D&nbsp;</span></span></span></p><h2 id="isPasted"><strong>Comfort Keeps Drivers Ahead of the Game<br></strong></h2><p>Because the number of things that can go wrong is staggering to comprehend during a race, the last thing a team wants is for the driver to lose his attention for a moment and hit a wall. As he grapples with continuous vibrations, severe jerking, and intense heat, the driver needs to feel at ease and be comfortable inside the car to perform to the best of his abilities. Comfort will contribute to maintaining his focus at a high pace for an extended period of time, which is essential to reach the checkered flag.</p><h2><strong>When 3D Scanning Makes a Difference in the Cockpit<br></strong></h2><p>Engineers at WTRAndretti have understood it: comfort inside the cockpit plays a crucial role in endurance racing. The ergonomics of the cockpit and everything inside it must be carefully designed to ensure that the driver has nothing to worry about except driving. More precisely, every piece that interacts with the driver, such as the seat, the steering wheel and the pedals, must be carefully positioned, as well as the sequence of movements and commands that the driver must repeat with deftness and dexterity during a race.</p><p>If drivers do not feel comfortable while experiencing jolts and vibrations, they will be less efficient, tire more easily, and make mistakes that could impact their performance and safety.</p><blockquote><p><em>&nbsp;<em style='color: rgb(117, 117, 117); font-family: "PT Serif", serif; text-align: left; background-color: transparent; display: inline !important;'>As a driver, making changes to make you feel comfortable in the car makes such a big difference, especially in sports car racing.</em></em></p><p>-Ricky Taylor, WTRAndretti Driver</p></blockquote><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689243090527-ricky-tyler-pilot-wtr.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">WTRAndretti-Pilot Ricky Taylor after an endurance race&nbsp;</span></span></span></p><h2 id="isPasted"><strong>Creaform Technology Standing Out</strong></h2><p>Equipped with the same Creaform technology&mdash;the <a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan" target="_blank">MetraSCAN 3D</a>&mdash;that was used to ensure the car&rsquo;s aerodynamics (<a href="https://www.creaform3d.com/blog/how-3d-scanning-optimizes-the-underbody-aerodynamics-of-race-cars/" target="_blank">as portrayed in our first article story</a>), the engineers were able to scan the entire interior of the<a href="https://waynetaylorracing.com/carspecs/" target="_blank">&nbsp;No. 10 Konica Minolta Acura ARX-06</a> and determine the driver&rsquo;s positioning alongside every component inside the cockpit. At the driver&rsquo;s request, the team could create a basic bracket made of a single piece that made a big difference. Not only could it match their multi-million dollar race car, but it was also mounted precisely not to alter the driver&rsquo;s position and comfort in the cockpit.</p><p>So now, thanks to this simple improvement, the driver is well-prepared and feels comfortable inside the car.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689243132188-wtr-racing-car-reverse-engineering-part.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">3D model of a special bracket obtained by reverse engineering the cockpit&nbsp;</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689243142295-wtr-cockpit-ergonomy-part-2.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">Special part designed and mounted to optimize the ergonomics of the cockpit&nbsp;</span></span></span></p><h2 id="isPasted"><strong>Getting Everything Right Results in Wins<br></strong></h2><p>WTRAndretti is putting all the pieces in place to maintain their winning streak and secure future victories and championships. Creaform will continue to support them throughout the upcoming races. We are excited to witness the drivers&rsquo; achievements and the enhancements that 3D scanning technology will bring to the endurance and performance of WTRAndretti&rsquo;s state-of-the-art racing cars.</p>

Endurance racing does not only require the best and latest technology. It also involves having the ability to harness it for multiple hours in a row without causing disaster. When you are competing at the highest level and against the best of the best, attention to detail is everything. This means leaving no stone unturned, no issue unresolved. Only then can a racing team truly be at the top of its game.

3d scanning

Profiles