3d scanning

<h2>The Search for a Universal Algorithm</h2>For robots to keep up with the pace of technological innovation, machine learning has become paramount. While robots are already effective at alleviating the manual operation of routine tasks, an intelligent robot should also be able to process their commands with future actions in mind. Engineers at <a href="https://www.facebook.com/robotechvision/" target="_blank">RoboTech Vision Ltd.</a>, Peter P&aacute;szt&oacute;, PhD., Marian Kľ&uacute;čik, and Martin Smoľ&aacute;k are focused on that pursuit by developing autonomous mobile robots for outdoor environments. This is where Clearpath&rsquo;s <a href="http://bit.ly/2X7wQRW" target="_blank">Husky UGV</a>, a medium sized robotic development platform, fits in.What was RoboTech Vision&rsquo;s goal with this technology collaboration? They wanted to utilize the Husky to debug their location and navigation algorithms. This step would enable them to effectively develop and deploy artificial intelligence on their own mobile robots. Furthermore, they are focused on using Husky for their research on robot learning, voice commanding, and object recognition. Clearpath not only provided a mobile base for their process but also served as a catalyst for their ROS experiences, particularly in the advances of their own algorithms and software resources.<h2>Androver 2: Autonomous Navigation via Mobile Devices</h2>RoboTech Vision&rsquo;s unique approach is implementing the elements of artificial intelligence in addition to autonomous navigation. They believe that this provides better interaction with the user, prediction, and decision making in some situations. The objective is a robot that can understand verbal commands, learn and create logical links to the objects with commands, and use it to perform tasks.<iframe src="https://www.youtube.com/embed/_ytgnlVJZhw?&wmode=opaque" frameborder="0" allowfullscreen="" class="fr-draggable" style="width: 1115px; height: 636px;"></iframe>RoboTech Vision customized Husky (robotic arm&nbsp;<a href="https://store.clearpathrobotics.com/products/universal-robots-ur5" target="_blank">UR5</a>&nbsp;attached) by adding a camera capable of recognizing and following objects without human intervention.&nbsp;Before adopting Husky, RoboTech Vision found that developing their own solution had been overly time-consuming. Clearpath&rsquo;s robotics platform gave them the freedom to divide their team into two parts: 1) Development of algorithms (using Husky) and 2) Development of their own robot, Androver 2. The Androver 2 is a prototype of a four-wheeled mobile robot with a Double-Ackerman kinematic structure, designed primarily for outdoor environments. The versatile and customizable robot uses artificial intelligence for autonomous navigation and performs many different types of tasks. For example, Androver 2 has undergone successful day and night tests at the European Space Agency on the simulated surface of the Moon for their simulated space missions.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1579089626410-Androver-2-on-Istrobot-competition.jpg">Androver 2 at the international competition Istrobot where it won first place. Its task was to move to a specified point as quickly as possible and return to the start. Image source: RoboTech Vision/ Mari&aacute;n T&aacute;rn&iacute;k<h2>Collaborative Force</h2>RoboTech Vision&rsquo;s main motivator for working with Clearpath was that Husky had a different kinematic structure than their own platform, Androver 2. This made it ideal for testing their algorithms on different models during development. &nbsp;The main goal: a universal algorithm that can work on a variety of robots. By adopting the Husky robotic platform, they were able to save time as they did not have to independently develop their own platform for testing and developing their algorithms.RoboTech Vision followed several different steps to make Husky their own:<ul><li>Upgrade of the Husky with a GPU to increase its computing power. This fulfilled their needs of implementing their AI and visual system algorithms. Lastly, this also gave them the ability to use computationally intensive neural networks, which is what is behind recognizing objects or detecting a suitable path.</li><li>Addition of their own Axis camera for visual input.</li><li>Adjustment of the mount for the Novatel GPS to improve reception.</li><li>Creation of a superstructure and extra ventilation to support the Nvidia graphics card</li></ul><h2>Technical Applications</h2>For mapping purposes, RoboTech Vision uses a <a href="https://store.clearpathrobotics.com/products/puck" target="_blank">LiDAR Velodyne Puck</a>. The Velodyne with the Axis camera allows them to both detect obstacles and&nbsp;recognize objects. Their <a href="https://store.clearpathrobotics.com/products/hokuyo-ust-10lx" target="_blank">2D Hokuyo UST-10LX LiDAR</a> is mostly used for area monitoring, as they rely on a 3D scanner to detect obstacles. Finally, the UR5 robotic arm integrated by Clearpath will enable the robot to grasp recognized objects in the future.<iframe src="https://www.youtube.com/embed/32LSzpZ0kC0?&wmode=opaque" frameborder="0" allowfullscreen="" class="fr-draggable" style="width: 1114px; height: 629px;"></iframe>Here is an example of RoboTech Vision using their Object Tracking Algorithm with Husky. It is able to recognize and follow objects at a safe distance using a camera with a 3D scanner.&nbsp;<h2>The Clearpath Advantage</h2>According to RoboTech Vision, the Husky was effective at helping them progress towards their goal of creating a universal algorithm which would assist with their autonomous mobile robots. They chose Husky as their mobile base because it is &ldquo;well crafted and relatively easy to upgrade&rdquo;. The opportunity to combine both their own technology with that of Clearpath, was extremely attractive to them. Finally, they believe that in terms of engineering and reliability, the Husky platform performs on a higher level than the competition. The Husky&rsquo;s technical specifications alongside Clearpath&rsquo;s focus on cooperation and collaboration made the Husky the best option for them. &nbsp;&nbsp;RoboTech Vision&rsquo;s foray into universal algorithms continues with their research work and alongside Husky they will continue to effectively manage their projects and complement their technology. Beyond the Andover 2, they will look to apply their algorithms to a variety of solutions including robotics, web applications, android development, and hardware development.

RoboTech Vision is a Slovakia based software company that works in the fields of robotics, visual systems, web applications development, custom software, and mobile applications development.  Image source: RoboTech Vision.

For robots to keep up with the pace of technological innovation, machine learning has become paramount. While robots are already effective at alleviating the manual operation of routine tasks, an intelligent robot should also be able to process their commands with future actions in mind.

Developing A Universal Algorithm For Mobile Robots With Husky UGV

SCANTECH 3D

Surface roughness can be measured with a profilometer

Measuring surface roughness allows metrologists to establish the roughness of a surface for quality control or other purposes. But how exactly is it done?

Measuring Surface Roughness: A Comprehensive Guide

Point clouds are an important concept in 3D scanning and <a href="https://www.wevolver.com/article/how-to-make-a-3d-model-for-printing" target="_blank" rel="noopener noreferrer">3D modeling</a>. Sometimes consisting of tens of millions of individual data points, point clouds can represent anything from a tiny piece of jewelry to an entire football stadium.So what exactly are point clouds? Where do they come from and how are they used? This article goes over the essential facts, looking at the basics of 3D scanning, point cloud formats, and point cloud software.<h1 dir="ltr">What is 3D scanning?</h1>Before we get into the nitty gritty of point clouds, we should take a moment to familiarize ourselves with 3D scanning.3D scanning is the process of taking a physical, real-world object — an industrial part, a piece of pottery, a human being… you name it — and collecting data about its 3D shape in order to create a digital 3D model of it.There are a few variations on the 3D scanning process, all of which use slightly different methods to collect data about an object’s shape. Some of the most common 3D scanning technologies include:<ul><li dir="ltr">Laser scanning: A laser is shined at the object, and a sensor measures the distance between the light source and the surface of the object, either by timing how long it takes for the light to return (“time of flight” or Lidar) or by triangulation.</li><li dir="ltr">Structured light scanning: Patterned lines of light are projected onto the object, and cameras are used to analyze how the lines deform over the surface of the object. These deformations indicate the shape of the object.</li><li dir="ltr">Photogrammetry: Photographs are taken of the object from many different angles, and software stitches these images together to figure out the 3D shape of the object.</li></ul>The use cases for 3D scanning are nearly endless. In various industrial disciplines, scanners can be used for reverse engineering: a part can be scanned, turned into a digital 3D model, then reproduced in physical form. Other applications include surveying (in areas like construction and civil engineering) using photogrammetry, building information modeling (BIM), crime scene analysis using handheld 3D laser scanners, capture of real-world objects for animation and video games, and scanning body parts in medicine and dentistry.3D scanning is also widely used in tandem with digital manufacturing techniques like 3D printing and CNC machining, as scan data can be converted into a CAD model or into a mesh format such as STL, which can then be turned into <a href="https://www.wevolver.com/article/your-guide-to-3d-printing-g-code" target="_blank" rel="noopener noreferrer">machine-readable G-code</a>.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY3OTgwMDkxMjQ5LTNkX3NjYW5uZXIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib" alt="structured light">Structured light scanning for reverse engineering<h1 dir="ltr">What is a point cloud?</h1>A point cloud is the immediate digital output of the 3D scanning process. When you use a 3D scanner to capture the shape of a physical object, the resulting file format is a point cloud.In short, a point cloud is a collection of spatial data points, with each individual point representing a tiny spot on the surface of the scanned object (collected using one of the technologies described above). The point is expressed as a set of X, Y, Z coordinates. Because there are so many of these individual data points, the point cloud as a whole can be used to understand the 3D shape of the scanned object.However, not all point clouds are equal: more data points and a higher-density point cloud means more detail, whereas a point cloud with just a few data points will only give an approximate representation of the real-world object. That being said, high-density point clouds require more computer memory and processing power.So how many individual points does a 3D point cloud contain? This varies by the size of the scanned object and the chosen resolution of the scan, but the number is typically in the millions. This makes the processing of point cloud data fairly CPU-intensive.Depending on the scanning technology, a data point in a point cloud may also contain RGB color (and brightness) information.<h1 dir="ltr">Point cloud file formats</h1>There are a few different file formats for point clouds, which can make the handling of the raw data confusing. However, most formats fall into two categories, and many are similar to one another and therefore easy to convert. Some formats are universal, while others are proprietary and have been developed by 3D scanning hardware manufacturers.<h2 dir="ltr">ASCII</h2>The first major type of point cloud format is ASCII (American Standard Code for Information Interchange), which conveys information using text. Each line of text within an ASCII point cloud represents X, Y, Z spatial coordinates.Common ASCII extensions: XYZ, OBJ, ASC, PTX<h2 dir="ltr">Binary</h2>The other major type of point cloud format is binary, which retains all information in binary code. Although binary data is harder to access and interpret, the files themselves are much smaller than ASCII files.Common binary extensions: LAS, PCD, FLS<h1 dir="ltr">Turning a point cloud into a 3D model</h1>Point clouds are a highly effective way of arranging information about the physical world, but they are not particularly useful for further activity once stored on a computer. Although it is possible to use point cloud datasets directly, many users will ultimately convert the point cloud into one of the following file types:<ul><li dir="ltr">CAD model, allowing the 3D scan data to be modified (reverse engineering etc.)</li><li dir="ltr">NURBS surface model, turning the 3D scan data into a digital 3D object with curved surfaces (on-screen visualization, video game rendering etc.)</li><li dir="ltr">Mesh, turning the 3D scan data into a polygon or triangle mesh (3D printing etc.)</li></ul>The process of turning a point cloud into a 3D model is known as surface reconstruction. This is because a point cloud itself does not contain “surfaces,” only a multitude of discrete coordinates.Of course, the conversion of point cloud data into 3D models is not a simple process. Point cloud processing software must use algorithms to figure out how to represent a collection of points as lines or shapes while determining which data points are genuine and which are outliers. The best software uses deep learning to contextualize point clouds and understand what the data is supposed to represent.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY3OTgwMTU1MzQ1LXBvbHlnb25hbF9tZXNoLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib" alt="mesh">A point cloud can be transformed into a polygonal mesh<h1 dir="ltr">Point cloud processing software</h1>Users may need various types of software to create a smooth 3D scanning workflow. However, one of the most important tools is point cloud processing software. This software is used to manually edit point clouds (to remove outlying data points, for example) and render them visually. Different algorithms can be deployed to automatically filter outlying data points.[1]Functions of point cloud processing software may include:<ul><li dir="ltr">Manual editing of the point cloud</li><li dir="ltr">Automatic cleanup and filtering</li><li dir="ltr">Offloading tasks to the cloud</li><li dir="ltr">Rendering</li><li dir="ltr">Point distance calculation</li><li dir="ltr">Registration</li><li dir="ltr">Conversion to mesh</li><li dir="ltr">Conversation to NURBS</li></ul>Popular point cloud processing software includes CloudCompare (free and open source), Point Cloud Library (free and open source), Leica Cyclone, Faro Scene, Autodesk Recap, and Trimble RealWorks.<h3 dir="ltr">Point cloud registration</h3>For 3D scanning applications like product quality control and <a href="https://www.wevolver.com/article/3d-scanning-for-inspection-are-3d-scanners-a-smart-choice" target="_blank">inspection</a>, it may be necessary to perform a process known as point cloud registration, otherwise known as point-set registration or scan matching. The process also has numerous uses in computer vision applications.[2]This is when a point cloud is aligned with another point cloud (or a 3D model) that represents the same physical object. Registration serves a few different purposes, including the merging of two or more data points from separate scans to create a more accurate data set (when using two different scanning technologies to capture a single object, for example), and the comparison of one cloud with another in order to note any discrepancies.&nbsp;One application of point cloud registration is in quality control, where a point cloud obtained from a 3D scan of a manufactured part can be compared with a point cloud from the original CAD model for the part. This can show whether the manufactured part is faithful to the CAD model, or whether the manufacturing process has produced defects.<h1 dir="ltr">Making point clouds 3D printable</h1>3D scanning can be used in combination with 3D printing. This combination is useful for applications like fabricating spare and replacement parts: a 3D scanner can be used to capture a physical part; a 3D model can then be created (and modified) before being 3D printed, resulting in a duplicate of the original part.To make point cloud data 3D printable, it needs to be converted into a triangle mesh using mesh processing software such as MeshLab (free and open source). Such software can fix holes in the point cloud and turn it into a format such as STL, the standard format for additive manufacturing.Unlike a point cloud, an STL file describes the surface geometry of a 3D object through interconnected triangles. Such a file can be “sliced” by 3D printer slicing software to turn it into G-code, which instructs the 3D printer how to make the part.<h1 dir="ltr">Key takeaways</h1>All 3D scanning technologies produce point clouds. Whether you use a handheld 3D laser scanner, a desktop structured light scanner, or a photogrammetry setup with digital cameras, the digital output of your scans will be a point cloud.Processing the point cloud is not always straightforward, as dense clouds can be very large and CPU-intensive. However, there are good software options, including those packaged with 3D scanning hardware, as well as free applications like CloudCompare. Additionally, most users will need to perform surface reconstruction on their point cloud in order to create a 3D model that isn’t simply a collection of spatial data points.Once you have become familiar with point clouds and how to handle them, the applications are diverse, from 3D city mapping to animation to 3D printing.<h1 dir="ltr">References</h1>[1] Han XF, Jin JS, Wang MJ, Jiang W, Gao L, Xiao L. A review of algorithms for filtering the 3D point cloud. Signal Processing: Image Communication. 2017 Sep 1;57:103-12.[2] Huang X, Mei G, Zhang J, Abbas R. A comprehensive survey on point cloud registration. arXiv preprint arXiv:2103.02690. 2021 Mar 3.

3D scanners produce point clouds of varying densities

Beginners might be surprised to find that their 3D scans turn out not as solid 3D models, but as clusters of spatial data points. So what exactly is a point cloud, and what can you do with it?

Point clouds explained: scanning, processing, 3D models

In the manufacturing of grinding and milling equipment, roller shells are critical wear components used extensively in industries such as mining, cement, metallurgy, and power generation. These shells work under intense operating conditions, directly crushing abrasive materials including ore, coal powder, and cement clinker. Their surface is continually subjected to high pressure, strong friction, and severe impact. Therefore, accurately assessing the dimensional accuracy of new roller shells and evaluating wear on used ones is essential to ensuring equipment stability, optimizing repair processes, and lowering operational costs.As industrial production accelerates toward digital transformation, many manufacturers are gradually replacing traditional manual inspections with high-precision 3D scanning to achieve faster, more reliable, and more comprehensive measurement results.<h3>Challenges in Inspection and Wear Evaluation</h3>A grinding roller typically consists of a steel core with a replaceable roller shell fitted on the outside. These roller shells require frequent inspection throughout their lifecycle:<ul><li> Incoming inspection for newly machined roller shells to confirm dimensional accuracy, surface quality, and machining consistency.</li><li> Wear evaluation of in-service roller shells to decide on repair strategies such as overlay welding, machining, or replacement.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1764060725434-1.jpg" style="width:100%px" class="fr-fic fr-dib" />However, roller shells present several challenges:A single roller shell may weigh several tons. Most inspections must be done directly in workshops or repair sites, often in dusty, humid, or poorly lit environments. Although roller shells appear cylindrical, their surfaces can include chamfers, transition curves, welded repair regions, and uneven wear patterns. These details are difficult to assess with simple manual tools.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1764060738278-2.jpg" style="width:100%px" class="fr-fic fr-dib" /><h3 id="isPasted">Limitations of traditional methods</h3>Calipers, height gauges, or feeler gauges can only measure a few reference points. They lack the ability to capture full-surface geometry, visualize wear distribution, detect subtle deviations, and provide reliable data for repair decisions. <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1764060772844-3.jpg" style="width:100%px" class="fr-fic fr-dib" />This often results in:Low efficiency: inspections may take several hoursHigh labor dependency: accuracy varies with operator experienceInconsistent welding repair: excessive or insufficient welding leads to higher costs and more machining timeInadequate data traceability: no comprehensive records for long-term maintenance planning<h3>3D Scanning Solution and Workflow</h3>3D scanning technology provides a non-contact, full-field, digital inspection method ideal for large industrial components. SCANOLOGY's <a href="https://www.3d-scantech.com/product/nimbletrack-wireless-3d-scanning-system/" target="_blank">NimbleTrack intelligent wireless 3D scanning system</a> offers significant advantages in roller shell inspection.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1764060850952-4.jpg" style="width:100%px" class="fr-fic fr-dib" />1. Dimensional<a href="https://www.3d-scantech.com/solution/3d-inspection/" target="_blank"> Quality Inspection</a> for New Roller ShellsNimbleTrack captures complete 3D point clouds at high speed and converts them into a mesh model, which is then aligned to the CAD model to generate outputs such as color maps, edge comparisons, cylindricity and roundness analysis, and surface defect visualization. These results allow engineers to quickly pinpoint out-of-tolerance machining areas, including diameter or roundness deviations, taper inconsistencies, surface dents or machining marks, and incorrect chamfer angles, ensuring that every roller shell meets production standards before assembly.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1764060864770-5.jpg" style="width:100%px" class="fr-fic fr-dib" />2. Wear Analysis – Cross-Section MeasurementFor used roller shells, the system reconstructs the geometry and extracts cross-sectional slices at fixed intervals along the axis, fitting circles to each slice to measure diameter reduction, out-of-roundness, and overall deformation trends. Engineers then use this information to decide whether welding repair is needed, how much material should be added, and where localized wear is most severe.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1764060883050-6.jpg" style="width:100%px" class="fr-fic fr-dib" />3. Wear Analysis – Profile and Longitudinal GeometryThe 3D scanner generates high-density cross-axis profiles to evaluate uneven wear, surface pitting or erosion. By comparing the scanned data directly with the nominal model, manufacturers can optimize overlay welding volume, reducing machining workloads while maintaining precise shape accuracy.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1764060898836-7.jpg" style="width:100%px" class="fr-fic fr-dib" /><h3 id="isPasted">Key Advantages of 3D Scanning for Roller Shell Inspection</h3>1. Highly efficient on-site operationNimbleTrack's wireless, marker-free workflow is ideal for large components. Entire scans can be completed in minutes instead of hours.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1764060913958-8.jpg" style="width:100%px" class="fr-fic fr-dib" />2. High precision and stabilityWith an accuracy of up to 0.025 mm, the system reliably captures fine surface details that traditional tools cannot detect.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1764060924048-9.jpg" style="width:100%px" class="fr-fic fr-dib" /><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1764060934580-10.jpg" style="width:100%px" class="fr-fic fr-dib" />3. Full-field visualization and data traceabilityColor maps and historical comparisons allow engineers to make data-driven repair decisions and track equipment degradation over time.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1764060945404-11.jpg" style="width:100%px" class="fr-fic fr-dib" />4. Cost reduction and extended component lifespanA more accurate wear assessment results in reduced welding material usage, shorter machining times, fewer unnecessary component replacements, and improved overall equipment availability.<h3>Conclusion</h3>3D scanning offers a transformative upgrade for grinding roller shell inspection and wear analysis. It addresses the inherent limitations of manual measurement by delivering improved accuracy, higher efficiency, and full-surface evaluation. As the manufacturing industry moves toward smart, data-driven operations, advanced 3D scanning systems like SCANOLOGY's NimbleTrack will continue to play an essential role in ensuring product quality, optimizing repair processes, and reducing operational costs.

Advanced 3D scanning delivers comprehensive, high-accuracy inspection for massive grinding roller shells. It replaces manual measurement with fast, traceable digital analysis, enabling smarter maintenance and reduced operational costs.

3D Scanning for Grinding Roller Shell Inspection: Enhancing Efficiency, Precision, and Repair Quality

Precision Matters in Wind EnergyIn the wind power industry, turbine blades are at the heart of energy conversion. Their dimensional accuracy and structural integrity determine the efficiency, reliability, and service life of an entire wind turbine. However, as blades extend well beyond 100 meters in length, maintaining precision across their massive, complex geometry becomes a significant challenge—especially when it comes to a crucial component inside the blade: the core material.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1763345300531-01.jpg" style="width:100%px" class="fr-fic fr-dib" />This lightweight composite material fills the space between the blade's skin and spar cap, enhancing stiffness, stability, and load-bearing capacity. Any deviation in the core's dimensions can lead to poor fit during molding, increased rework, and even structural inconsistencies that affect blade performance. For years, this has been a persistent "core issue" for blade manufacturers.Customer BackgroundMingyang Smart Energy Group Co., Ltd. was founded in 2006 and has since become a leading global player in clean energy technology. The company's business covers wind, solar, storage, and hydrogen energy systems, as well as engineering services and intelligent energy solutions. Mingyang ranks No. 1 in offshore wind innovation and newly installed capacity worldwide in 2023, setting a benchmark for sustainable energy manufacturing.With its expanding production scale, Mingyang needed a more precise and data-driven solution to control the dimensional quality of wind turbine blades—especially during the molding and assembly stages where the core materials are installed.The Manufacturing ChallengeDuring blade production, core materials are pre-machined into one-meter segments and inserted into the leeward side between 21 and 40 meters along the blade length. Before this process, the factory relied mainly on theoretical CAD drawings to shape the core material. However, due to mold wear, process variation, and manual operation, the real geometry of each blade section often differs from the design.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1763345320777-03.jpg" style="width:100%px" class="fr-fic fr-dib" />This discrepancy results in:Poor core fitting — gaps or overlaps during assemblyFrequent rework — manual trimming, filling, and patching on-siteMaterial waste — discarded composite materials after failed fittingExtended production cycles — delayed assembly and quality re-inspectionTraditional measurement tools such as tape measures and calipers are insufficient for capturing complex 3D contours. They can only measure discrete points, not continuous curved surfaces, leading to inaccurate data. The lack of reliable digital geometry not only slows down production but also prevents accurate feedback for mold adjustment and design optimization.The 3D Scanning SolutionTo address these challenges, Mingyang adopted SCANOLOGY's KSCAN-E 3D scanning solution. The <a href="https://www.3d-scantech.com/product/kscan-e-intelligent-and-wireless-flagship-all-in-one-3d-scanner/" target="_blank">KSCAN-E wireless all-in-one 3D scanner</a> combines photogrammetry and laser scanning to deliver high precision, high speed, and full-area 3D data acquisition—ideal for large-scale and freeform surfaces like wind turbine blades.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1763345344314-05.jpg" style="width:100%px" class="fr-fic fr-dib" />The entire scanning workflow was designed to ensure both accuracy and efficiency, even in the complex, confined space of the blade interior.Step 1: Pre-bonding ScanningBefore bonding the blades, engineers used the KSCAN-E to scan the upper and lower edges of the leeward side between the 21-meter and 40-meter sections. This captured the real-world 3D data, providing a digital foundation for subsequent machining of the core material.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1763345358145-06.jpg" style="width:100%px" class="fr-fic fr-dib" />Step 2: Post-Molding AlignmentAfter bonding, the same section was rescanned to capture the reference markers previously attached to the blade's inner surface. These markers serve as coordinate references, ensuring that both sets of scan data are aligned within the same reference frame.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1763345370689-07.jpg" style="width:100%px" class="fr-fic fr-dib" />Step 3: Data Processing and 3D ReconstructionUsing SCANOLOGY's DefineSight software, engineers automatically aligned and merged the pre- and post-bonding 3D data to create a complete, high-precision 3D model. This digital model accurately represents the real shape of the blade's inner surface and can be exported in standard file formats (such as STL or STEP) for direct use in CAD/CAM systems.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1763345386065-08.jpg" style="width:100%px" class="fr-fic fr-dib" />The digital data is then sent to the core material supplier, who can precisely machine each core section according to the actual blade geometry—ensuring a perfect fit during assembly.The Results1. Precision Data Enables Smarter ManufacturingWith the KSCAN-E, engineers can now obtain accurate 3D data of the blade's complex edges within minutes. The scanner's precision—up to 0.020 mm—ensures that every subtle curvature is faithfully captured. This eliminates uncertainty caused by relying solely on theoretical models and establishes a digital foundation for quality control, mold calibration, and design iteration.All scan data is archived, forming a traceable digital record that supports continuous improvement in blade production.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1763345399951-09-1.jpg" style="width:100%px" class="fr-fic fr-dib" /><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1763345409186-09-2.png" style="width:100%px" class="fr-fic fr-dib" />2. Seamless Assembly and Higher EfficiencyBy machining the core material based on real scanned data, the fitting accuracy has improved dramatically. Each core section now matches the blade cavity with near-perfect precision, allowing for fast, seamless installation. This has almost completely removed the need for manual trimming or padding, reducing the assembly time significantly and enhancing the overall production rhythm.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1763345420890-10.jpg" style="width:100%px" class="fr-fic fr-dib" />3. Cost Reduction and Waste PreventionThe transition from manual correction to "first-time-right" manufacturing has led to remarkable cost savings. The elimination of rework reduces both material waste and labor hours, while improved consistency helps stabilize downstream production planning. In essence, SCANOLOGY's 3D scanning solution delivers measurable returns by combining efficiency, precision, and sustainability.Project SummaryThis project demonstrates how SCANOLOGY's advanced 3D scanning technology can fundamentally transform wind turbine blade manufacturing. The KSCAN-E's wireless operation ensures smooth mobility even inside narrow spaces, removing the risk of cable entanglement and improving on-site safety.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1763345439340-11.jpg" style="width:100%px" class="fr-fic fr-dib" />The resulting high-precision 3D models serve as a reliable digital reference for machining, inspection, and virtual assembly, preventing mismatched components and costly rework. More importantly, the entire process becomes data-driven and predictable, enabling manufacturers to shift from reactive correction to proactive control.By integrating SCANOLOGY's 3D measurement solutions, Mingyang has built a standardized, digitalized, and intelligent manufacturing workflow for wind turbine blades. This success not only enhances production efficiency and quality but also sets a new benchmark for digital transformation in the global wind energy sector.

SCANOLOGY's 3D scanning empowers wind turbine blade manufacturers to precisely control core dimensions, eliminate rework, and achieve seamless assembly—turning a long-standing "core challenge" into data-driven manufacturing excellence.

How SCANOLOGY's 3D Scanning Solves the "Core" Challenge in Wind Turbine Blade Manufacturing

<a href="http://www.revopoint3d.com">Revopoint</a> has added three new devices to its 3D scanner portfolio: <a href="https://www.revopoint3d.com/pages/inspire2-infrared-laser-3d-scanner">the INSPIRE 2</a>, <a href="https://www.revopoint3d.com/pages/metroy-3d-laser-scanner">MetroY, and MetroY Pro</a>. Each scanner is built to meet the precision and portability demands across industries. Equipped with the latest hardware optical systems, Revopoint’s scanners support innovations in 3D printing, quality inspection, product design, reverse engineering, digital animation, and cultural heritage preservation.Beyond the hardware, Revopoint offers free Revo Metro software. It is a one-stop solution for your workflow from data acquisition to model optimization. The software enables users to import models into post-processing tools such as Quicksurface, Geomagic Wrap, and Geomagic Control. This compatibility ensures an efficient scan-to-CAD workflow, so that users can focus on innovation rather than tedious processing.In this article, we’ll explore the features, specifications, and real-world applications of the INSPIRE 2 and MetroY series. We will also highlight how these scanners improve workflows in design, manufacturing, media, and preservation projects.<h1>Product Features</h1>This section introduces the key capabilities of the INSPIRE 2 and MetroY series. It also sheds light on how their technology addresses challenges in scanning<h2>INSPIRE 2</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzYxMTQxNDY2NDY5LXVubmFtZWQgKDkpLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width:100%px" class="fr-fic fr-dib" />From desk to digital: INSPIRE transforms objects into 3D designs.The INSPIRE 2 is designed for those who want a balance between portability and accuracy in a wide range of projects. The combination of laser and structured light scanning tech makes it flexible for both technical and creative work.<h3>Dual-Mode Scanning</h3>One of the standout features is its dual-module scanning system, which comprises infrared structured light and parallel laser modes. Its 11 parallel infrared laser lines capture details on even dark or shiny surfaces without the need for scanning spray. The infrared structured light mode can capture high-quality body and face scans without using markers.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzYxMTUxMjEwMjI1LXVubmFtZWQgKDEwKS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width:100%px" class="fr-fic fr-dib" /><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzYxMTUxMjE4NDA0LXVubmFtZWQgKDMxKS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width:100%px" class="fr-fic fr-dib" />Scanned motorcycle casing (Laser mode, Revopoint INSPIRE 2 3D Scanner). Credit: Tony Hzr.<h2 id="isPasted">30% More Detail</h2>Thanks to upgraded depth cameras, the INSPIRE 2 provides 30% more surface detail and a 30% larger capture area. This enhancement improves tracking and accuracy when working on medium-sized objects or multi-angle scanning projects.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzYxMTUxMjczODYxLXVubmFtZWQgKDExKS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width:100%px" class="fr-fic fr-dib" />Scanned plastic screw, 8cm long (infrared structured light with markers, Revopoint INSPIRE 2 3D Scanner). Credit: 3DVF.<h2 id="isPasted">Reliable Outdoor Scanning</h2>Unlike many structured light scanners that struggle in bright conditions, the INSPIRE 2 performs reliably in environments up to 20,000 lux. It can handle shaded or semi-bright outdoor settings without losing accuracy.<h2>Adjustable Optical Zoom</h2>The latest optical zoom system with 1.5x and 2x magnification allows for fine-tuned scans depending on surface complexity. By focusing the projected light field, the zoom feature enhances surface detail capture, which is crucial in design applications.<h2>Wireless Connectivity and Portability</h2>Equipped with a Wi-Fi 6.0 module, the INSPIRE 2 ensures fast and stable wireless connections to both computers and mobile devices. Its wire-free operation allows for on-the-go work indoors as well as in the field.<h2>MetroY Series (MetroY and MetroY Pro)</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzYxMTUxMzQzMzA5LXVubmFtZWQgKDEzKS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width:100%px" class="fr-fic fr-dib" />MetroY capturing 3D data for reverse engineering applications.<h2 id="isPasted">MetroY</h2>The MetroY provides three versatile modes: cross, parallel, and single line. These configurations scan at up to 1.7 million points per second, offering speed without compromising on detail.The onboard HD RGB camera enhances the quality of scans by capturing realistic texture data and color information. This is ideal for applications where both visual and geometric fidelity are important, such as product design and art restoration.The addition of Wi-Fi 6 connectivity enables untethered operation. It offers users the freedom to move around objects in labs and industrial settings without worrying about cable clutter.<h2>MetroY Pro</h2>Building upon the strengths of the base model, the MetroY Pro introduces a range of additional features to deliver higher precision and automation. Along with the three standard blue laser modes, the MetroY Pro comes with two more scanning modes:<h3>Full-Field Structured Light Mode:</h3>This mode captures up to 7 million points per second, enabling highly detailed and marker-free scanning of complex geometries and textured surfaces. It’s particularly useful for reverse engineering and metrology-grade applications.<h3>Auto Turntable Mode:</h3>As its name suggests, the turntable mode rotates objects during capture. By minimizing human intervention in the workflow, it reduces scanning errors during 360-degree coverage and speeds up the overall process. This mode is useful for creating detailed and color-accurate 3D models.<a href="https://forum.revopoint3d.com/u/samlilly2" target="_blank" rel="noopener noreferrer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzYxMTUxMzk5ODYwLXVubmFtZWQgKDE0KS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width:100%px" class="fr-fic fr-dib" />Scanned Mazda 2.3 DOHC cylinder head (Parallel Line - Black Object mode, Revopoint MetroY Pro 3D Scanner). Credit: Samlilly2.</a><h1 id="isPasted">Real-World Applications</h1>Specs are impressive on paper, but the true value of these scanners lies in how they perform in real-world engineering and creative workflows. This includes prototyping, quality control, animation, and preservation.<h2>Reverse Engineering</h2>Reverse engineering traditionally involves tedious manual measurements, diagrams, and extensive documentation. Revopoint simplifies this process with advanced scanning technology. The MetroY uses blue laser scanning to capture even complex geometries with sub-millimeter accuracy. This enables engineers to fabricate replacements for legacy and discontinued components with minimal effort.<img alt="MetroY-Reverse Engineering" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzYxMTUxNDcwMjIwLTE3NjExNTE0NzAyMjAuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" width="599" height="374" class="fr-fic fr-dii" />Capture every complex geometric detail to create accurate 3D models ready for measurement or scan-to-CAD transformation for reverse engineering.<h2>Quality Control</h2>In industries such as aerospace, automotive, and medical devices, even tiny flaws can lead to serious consequences. The MetroY series specializes in detecting micro-defects such as hairline cracks in turbine blades or incorrect tolerances in prosthetic components. With color-textured output, these scanners make visual inspection more reliable.<img alt="image4.jpg" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzYxMTUxNDcwMjM5LTE3NjExNTE0NzAyMzkuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" width="602" height="339" class="fr-fic fr-dii" />Revo Metro software in action alongside MetroY for quality control application.<h2>3D Printing</h2>Revopoint scanners provide a fast and accurate way to capture objects and convert them into print-ready 3D models. This eliminates the need for time-consuming manual modeling in additive manufacturing.The INSPIRE 2, with its ultra-fine point distance of 0.05 mm, delivers detailed models for additive manufacturing. Such precision reduces the chances of print failures and wasted filament.<h2>Animation and Digital Media</h2>The INSPIRE 2's marker-free body scanning digitizes actors or props with ease. Its RGB imaging preserves skin tones and fabrics authentically for films or games. The outdoor scanning mode adds to the flexibility, allowing creators to scan on location in natural lighting conditions.<h2>Cultural Heritage and Preservation</h2>Historic artifacts require gentle handling. This is where Revopoint's 3D scanners' ability to capture detail with zero contact comes in handy.The resulting digital models serve not only as archival records but also as valuable references for restoration. Thanks to its lightweight and portable design, the INSPIRE 2 can be used at heritage sites when transporting sculptures or relics is not feasible.<h1>Conclusion</h1>With the INSPIRE 2 and MetroY series, Revopoint has raised the bar for 3D scanning by combining precision with ease of use. These scanners prove that you don’t have to sacrifice mobility to get accurate and reliable results.Whether you’re a hands-on tinkerer, an engineer in a large-scale manufacturing company, or a researcher working to preserve historical artifacts, there’s a Revopoint scanner that fits in your workflows. The INSPIRE 2 excels in creative and flexible pipelines, which makes it ideal for design, media, and on-site scanning. The MetroY series, on the other hand, is tuned for industrial-grade accuracy and automation.Explore more about  <a href="https://www.revopoint3d.com/pages/inspire2-infrared-laser-3d-scanner">INSPIRE 2</a> and <a href="https://www.revopoint3d.com/pages/metroy-3d-laser-scanner">MetroY Series</a>. Interested in carrying the Revopoint 3D Scanners? <a href="https://www.revopoint3d.com/pages/pr-become-a-dealer">Get in touch with Revopoint</a>.<h1>Specifications</h1>Understanding the specifications help engineers and designers select the right scanner for their requirements. The following table provides a detailed comparison of the INSPIRE 2 and MetroY series.<div><table><tbody><tr><td>Spec</td><td>INSPIRE 2</td><td>MetroY</td><td>MetroY Pro</td></tr><tr><td>Scanning type</td><td>Handheld and Desktop</td><td>Handheld</td><td>Handheld and Desktop</td></tr><tr><td>Scannable Object Size</td><td>Small to medium</td><td>Small to medium</td><td>Small to medium</td></tr><tr><td>Technology</td><td>Dual-camera Infrared Structured Light and Infrared Multi-line Laser</td><td>multi-line blue laser (3 modes)</td><td>multi-line blue laser + full-field structured light </td></tr><tr><td>Single frame precision</td><td>~0.03 mm</td><td>~0.01 mm</td><td>~0.01 mm</td></tr><tr><td>Single frame accuracy</td><td>~0.05 mm</td><td>~0.02 mm</td><td>~0.02 mm</td></tr><tr><td>Volumetric accuracy</td><td>0.05 mm + 0.1 mm × L</td><td>0.02 mm + 0.04 mm × L</td><td>0.02 mm + 0.04 mm × L (m</td></tr><tr><td>Fused Point Distance</td><td>0.1 mm</td><td>0.05 mm</td><td>0.05 mm</td></tr><tr><td>Working Distance (Indoor)</td><td>200 ~ 400 mm</td><td>200 ~ 400 mm</td><td>200 ~ 400 mm</td></tr><tr><td>Working Distance (Outdoor)</td><td>150 ~ 250 mm</td><td>NA</td><td>NA</td></tr><tr><td>Single Capture Area at Nearest Distance</td><td>130 × 129 mm at 200 mm</td><td>123 × 130 mm at 200 mm</td><td>152 × 138 mm at 200 mm</td></tr><tr><td>Single Capture Area at Furthest Distance</td><td>293 × 257 mm at 400 mm</td><td>290 × 260 mm at 400 mm</td><td>332 × 276 mm at 400 mm</td></tr><tr><td>Angular Field of View (H × V)</td><td>43 × 35°</td><td>43 × 33°</td><td>49 × 38°</td></tr><tr><td>Minimum Scan Volume</td><td>20 × 20 × 20 mm</td><td>10 × 10 × 10 mm</td><td>10 × 10 × 10 mm</td></tr><tr><td>Maximum Scan Volume</td><td>2 × 2 × 2 m</td><td>1 × 1 × 1 m</td><td>1 × 1 × 1 m</td></tr><tr><td>Scanning Speed</td><td>Full-field Structured Light Scan: 18 fpsMulti-line Laser Scan: 30 fps</td><td>Multi-line Laser Scan:1,500,000 Points/s</td><td>Multi-line Laser Scan: 1,700,000 Points/sFull-field Structured Light Scan:7,000,000 Points/s</td></tr><tr><td>RGB Camera Resolution</td><td>1280 × 800</td><td>2 Megapixels</td><td>2 Megapixels</td></tr><tr><td>Tracking Methods</td><td>Feature, Marker, Global Marker</td><td>Marker, Global Marker</td><td>Marker, Global Marker, Feature</td></tr><tr><td>3D Light Source</td><td>Class 1 Infrared Light</td><td>30 Blue Cross Laser Lines15 Blue Parallel Laser LinesBlue Single Laser Line</td><td>34 Blue Cross Laser Lines15 Blue Parallel Laser LinesBlue Single Laser Line62 Line Blue Full-field Structured Light</td></tr><tr><td>Fill Lights</td><td>4 Infrared LEDs</td><td>12 Blue LEDs</td><td>12 Blue LEDs</td></tr><tr><td>Output File Formats</td><td>PLY, OBJ, STL, ASC, 3MF, GLTF, FBX</td><td>PLY, OBJ, STL, ASC, 3MF, GLTF, FBX</td><td>PLY, OBJ, STL, ASC, 3MF, GLTF, FBX</td></tr><tr><td>Wi-Fi</td><td>6</td><td>6</td><td>6</td></tr><tr><td>Connector Type</td><td>USB Type-C</td><td>USB Type-C to Type-C</td><td>USB Type-C to Type-C</td></tr><tr><td>Scanner Weight</td><td>190 g</td><td>447 g</td><td>450 g</td></tr><tr><td>Dimensions (L × W × H)</td><td>53 × 27 × 132 mm</td><td>211 × 94 × 47 mm</td><td>211 × 94 × 47 mm</td></tr></tbody></table></div>

The INSPIRE 2 and MetroY series devices are built to accelerate workflows across engineering, design, and cultural preservation.

From Scan to Model in Record Time: Revopoint 3D Scanners Built for Efficiency

What does it take to stay ahead in the rapidly evolving marine vehicle industry, where every second counts? When DDD Control Kft., one of the top providers of 3D technology and post-processing software, set out to develop a new version of an electric jetski, they faced a key challenge: to design and manufacture a positive tool that perfectly aligned with an existing bottom hull model while reducing development time.<a href="https://www.3d-scantech.com/product/nimbletrack-wireless-3d-scanning-system/" target="_blank">NimbleTrack </a>is Scanology’s cutting-edge wireless optical 3D scanning system designed for flexible, high-precision measurements. It operates at a high frame rate of 120 FPS, achieving accuracy up to 0.025 mm and a volumetric accuracy of 0.064 mm across its 3.2-meter tracking range. Featuring a fully wireless design and marker-free optical tracking, NimbleTrack allows engineers to capture 3D data quickly and effortlessly — even for large or complex parts.To meet this challenge, DDD Control integrated Scanology's NimbleTrack wireless optical 3D scanning system into every stage of the design and validation process. Rather than limiting 3D scanning to final inspection, they used it as a core tool for real-time validation, design iteration, and geometry optimization. The result was a faster, more accurate, and cost-effective workflow that demonstrated the transformative potential of 3D scanning in tool design.<h2>Scanning of the Legacy Component</h2>The project began with the precise digitization of the jetski's existing bottom hull. Using Scanology NimbleTrack, the team captured a high-resolution 3D model of the component with submillimeter accuracy of up to 0.025 mm.This digital reference served as the foundation for all subsequent design work. It ensured geometric continuity between the legacy hull and the new version while eliminating guesswork from the design phase. The wireless and marker-free tracking capability of NimbleTrack also allowed engineers to scan large, complex surfaces effortlessly and in real time.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1761009323751-1.jpg" style="width:100%px" class="fr-fic fr-dib" /><h2 id="isPasted">Geometry Modification for the Bottom Hull</h2>With the scan data in hand, engineers extended the bottom hull to meet the new jetski's design specifications. Working directly with accurate 3D data enabled them to modify proven geometries confidently, ensuring that all changes maintained aerodynamic and hydrodynamic performance.This approach significantly reduced the time spent on manual adjustments and physical prototyping—key steps that often introduce delays in traditional workflows.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1761009338353-2.jpg" style="width:100%px" class="fr-fic fr-dib" /><h2 id="isPasted">Designing the Upper Hull</h2>Once the updated bottom hull model was completed, attention turned to designing the upper section of the jetski. The design team focused on aesthetic appeal, ergonomic considerations, and structural alignment with the extended bottom part.Because the lower hull data was already verified and precise, the upper design process progressed smoothly, with fewer uncertainties regarding fitment or dimensional consistency.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1761009352059-3.jpg" style="width:100%px" class="fr-fic fr-dib" /><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1761009362335-4.jpg" style="width:100%px" class="fr-fic fr-dib" /><h2 id="isPasted">Manufacturing and Validation of the Bottom Hull</h2>After the design phase, the modified bottom hull was manufactured. Before moving forward, the team used NimbleTrack 3D scanning once again to validate the hull’s accuracy.By overlaying the scan data onto the CAD model, DDD Control identified minor deviations early on. This quick feedback helped prevent potential alignment issues during later stages, saving both time and material costs.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1761009376677-5.jpg" style="width:100%px" class="fr-fic fr-dib" /><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1761009387176-6.jpg" style="width:100%px" class="fr-fic fr-dib" /><h2 id="isPasted">Design Adjustments for the Upper Hull</h2>The geometric insights gained from scanning the manufactured bottom hull guided targeted updates to the upper hull design. This proactive correction loop allowed the engineers to refine the fit between components before physical fabrication began.This level of iterative precision would have been impossible without real-time scanning feedback, which drastically minimized the risk of mismatch between the upper and lower assemblies.<h2>3D Printing of the Upper Part</h2>The upper hull was then 3D printed based on the refined design. Additive manufacturing offered excellent flexibility and speed, enabling rapid validation of the adjusted model. The printed prototype provided a tangible way to assess assembly, surface quality, and functional compatibility.<h2>Geometry Validation of the Printed Upper Part</h2>To confirm that the printed upper hull matched design expectations, the team performed another scan with NimbleTrack. The comparison showed that earlier adjustments successfully compensated for deviations, resulting in a near-perfect geometric match.This step validated the entire digital workflow and demonstrated how continuous 3D scanning feedback ensures design integrity at every milestone.<h2>Designing Additional Fitting Components</h2>With both main components validated, DDD Control designed secondary elements — such as connection interfaces and fitment features — based directly on the scanned geometry of the real parts. This ensured that all supporting structures were dimensionally consistent and ready for seamless integration.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1761009408833-7.jpg" style="width:100%px" class="fr-fic fr-dib" /><h2 id="isPasted">Final Fit and Validation</h2>The final assembly underwent one more comprehensive 3D scan to verify the accuracy of all surfaces and overall alignment. The validation confirmed dimensional integrity and precise fit across the entire positive tool.By closing the loop with one last scan, the team guaranteed that the final tooling met stringent accuracy standards without unnecessary iterations or rework.<h2>Outcome</h2>The integration of Scanology's NimbleTrack 3D scanning system proved to be a game-changer for this project.The scanning process reduced validation time by over 60% compared to traditional inspection methods.Early detection of dimensional deviations helped avoid costly rework and material waste.The project was delivered on a tight schedule while maintaining high precision and confidence in the final tooling outcome.Thanks to the real-time geometric insights provided by NimbleTrack, DDD Control achieved a smoother workflow from concept to completion — turning a complex design challenge into a streamlined, data-driven process.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1761009430135-8.jpg" style="width:100%px" class="fr-fic fr-dib" /><h2 id="isPasted">Key Takeaways</h2>3D scanning across all stages: Instead of using scanning only for quality control, DDD Control applied it throughout the entire design and manufacturing cycle, from reverse engineering to in-process validation.Fast, wireless, and accurate: Scanology's NimbleTrack enabled quick, repeatable scans of large parts without markers or elaborate setup, ensuring minimal disruption to ongoing production.Shorter iteration cycles: Real-time geometric feedback prevented fitment issues and accelerated decision-making.Precision-driven design: Continuous scanning ensured that every design update aligned perfectly with real-world conditions.<h2>Conclusion</h2>This case study highlights how 3D scanning technology is reshaping rapid tool design. By combining Scanology's NimbleTrack with iterative CAD modeling and additive manufacturing, DDD Control not only optimized accuracy but also accelerated the entire <a href="https://www.3d-scantech.com/solution/product-development/" target="_blank">product development</a> timeline.As industries increasingly move toward digitization and intelligent manufacturing, workflows like this demonstrate how integrated 3D scanning solutions can drive innovation, from marine vehicles to aerospace components, with precision, agility, and confidence.

Discover how DDD Control accelerated electric jetski tool design using Scanology's NimbleTrack 3D scanner, achieving high precision, faster validation, and reduced production time.

3D Scanning

Engineers Wiki.

Most Asked Questions.

Measuring Surface Roughness: A Comprehensive Guide

Point clouds explained: scanning, processing, 3D models

ORGANIZATIONS.

SHAPING THE INDUSTRY.

Creaform

Photoneo

SHINING 3D

Scanology

Revopoint International Limited

TAGGED WITH laser scanners

3D Scanning for Grinding Roller Shell Inspection: Enhancing Efficiency, Precision, and Repair Quality

How SCANOLOGY's 3D Scanning Solves the "Core" Challenge in Wind Turbine Blade Manufacturing

From Scan to Model in Record Time: Revopoint 3D Scanners Built for Efficiency

Rapid Tool Design for an Electric Jetski Using 3D Scanning

Latest Posts

Developing A Universal Algorithm For Mobile Robots With Husky UGV