3d scanning

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.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.See WTRAndretti&rsquo;s engineers and drivers in action on the race track.<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><h2 id="isPasted">3D Scanning Helps Put Every Piece at Its Place</h2>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.<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">WTRAndretti engineer scanning a special part with the Creaform MetraSCAN 3D&nbsp;<h2 id="isPasted">Comfort Keeps Drivers Ahead of the Game </h2>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.<h2>When 3D Scanning Makes a Difference in the Cockpit </h2>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.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.<blockquote>&nbsp;As a driver, making changes to make you feel comfortable in the car makes such a big difference, especially in sports car racing.-Ricky Taylor, WTRAndretti Driver</blockquote><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">WTRAndretti-Pilot Ricky Taylor after an endurance race&nbsp;<h2 id="isPasted">Creaform Technology Standing Out</h2>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.So now, thanks to this simple improvement, the driver is well-prepared and feels comfortable inside the car.<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">3D model of a special bracket obtained by reverse engineering the cockpit&nbsp;<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">Special part designed and mounted to optimize the ergonomics of the cockpit&nbsp;<h2 id="isPasted">Getting Everything Right Results in Wins </h2>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.

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.

Getting All the Details Right: The Key for Winning Endurance Races

<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688729256123-1-1024x471.jpeg" style="width: 766px;" class="fr-fic fr-dib">A multitude of old sea fossils, such as dinoflagellates (single-celled marine organisms), can be found in the soil of the Arabian Peninsula. Dinoflagellates are a subgroup of plankton that are responsible for a large portion of the oxygen in the atmosphere. They are also fundamental to the food pyramid. The Kuwaiti artist Monira Al Qadiri took inspiration from these dinoflagellates to create five larger-than-life Zephyr structures made from acrylic glass.The German company&nbsp;<a href="https://www.heinz-fritz.de/en/" target="_blank">Heinz Fritz GmbH</a> supported her in this project. Heinz Fritz GmbH primarily manufactures transparent plastics, such as acrylic glass (PMMA) and polycarbonate (PC), but also provides products made from engineering plastics, such as POM, PE, PTFE, etc. The products they offer range from blank cutouts, milled parts, and molded and glued parts to complex modules and XXXL assemblies. Heinz Fritz GmbH predominantly acts as a supplier for a range of well-known companies within the engineering and lighting industry. However, the company also regularly supplies facade components to architects, pieces of art and sculptures to artists, and aquarium glass to zoos.<h2>Data for the Milling Machine</h2>The company uses high-precision 5-axis portal milling machines with a working area of up to 20&nbsp;m x 5&nbsp;m x 2.5&nbsp;m. The STL data acquired with the 3D scanner and generated by the VXelements software can be processed directly with the CAD and CAM systems available at Heinz Fritz GmbH. Usually, parametric data serves as the basis for milling operations but, for very complex shapes, an additional scan offers increased productivity and production reliability. This makes it possible to connect the virtual world with reality with all the associated tolerances.Before 3D measurement technology was used, the required data had to be determined with a probing method. The more complex the shape of a component, the more complex it is to determine all the required points. The&nbsp;<a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d" target="_blank">Creaform 3D scanning system</a> is currently helping the company generate 3D data, install components, and assess target and actual versions of manufactured components.&ldquo;We were looking for a solution that would not only simplify our work, but that would also increase accuracy. In this sense, the Creaform system impressed us with the accuracy it is able to achieve for larger components too. The deciding factor for us was&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms" target="_blank">the easy-to-use functionality of the VXelements software and the direct output in .stl format</a>&rdquo;, explains Mr. Jakob Sixl, Managing Partner at Heinz Fritz GmbH. &ldquo;The intuitive operation of the 3D scanner and VXelements software allowed us to gain initial experience even before the training with a Creaform team member began. This meant that it was easy for us to get started and even work on concrete example cases and look at individual problems during the training phase.&rdquo;<h2>Producing Art from the Milling Machine</h2>The artwork known as &ldquo;Zephyr&rdquo; consists of five acrylic glass sculptures that are lit from beneath in order to recreate the organisms&rsquo; bioluminescence. It is a permanent installation at West Beach Front in Doha. The project provides a 20,000x magnification of microscopic organisms, known as dinoflagellates, that are found in almost all bodies of water across the world. The sculptures aim to reveal the crucial role that small, invisible creatures have to play as well as to demonstrate the importance of sea life. ZEPHYR is also a colourful reminder of the history of the region&rsquo;s ecosystem, and with it, the need to safeguard its longevity in the face of rapid modernization.<a href="https://www.heinz-fritz.de/en/projekte/art-and-objects/5-larger-than-life-sculptures/" target="_blank">Heinz Fritz GmbH helped to create these sculptures</a>. Based on 3D data provided by the artist, the high-precision 5-axis milling machine was used to mill the sculptures out of solid Plexiglas&reg; blocks. For this, <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" target="_blank">VXmodel software</a> helped to process and optimize the data that was provided. The dimensions of the sculptures amount to 3.2 m x 2.4 m with a thickness of over 900 mm.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688729285450-2023-04-26-16_18_47-Window.webp" style="width: 766px;" class="fr-fic fr-dib">After the milling process, each sculpture was scanned using the&nbsp;<a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d" target="_blank">Go!SCAN SPARK</a>. &ldquo;<a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms" target="_blank">VXelements software</a> was particularly useful for this as it significantly facilitated data processing and, thereby, enhanced our existing CAD and CAM systems,&rdquo; says Mr. Sixl.&ldquo;Recently, it has become increasingly common to use 3D measurement technology as an almost go-to choice and we&rsquo;re constantly finding new possibilities for the implementation of this technology. This primarily increases our quality standards, but it also increases productivity and production reliability too, often reducing working time. We&rsquo;ve not yet explored all the possibilities that the 3D scanner offers, and I believe there&rsquo;s more to come. We&rsquo;re working hard to use 3D measurement technology to find new solutions to problems,&rdquo; explains Herr Sixl.

3D scanning can be used to measure objects of art in order to assess their 3D dimensions accurately.

Using 3D Scanning in Art

First article inspection (FAI) is a crucial step in the manufacturing process. The quality control (QC) team needs to optimize this phase of inspection in order to limit the back and forth between conception and fabrication. The QC team must not only correctly identify the defects, but also provide relevant data, measurements, and results for solving the identified problems.&nbsp;Too often, quality managers are seen as those who seek and find problems&mdash;information that we obviously would rather do without. However, if the implementation of effective tools could enable them to not only identify problems, but also to find viable solutions, it would help production to progress more quickly, and the first articles could be delivered without delays and complications.This blog explores the evolution of new technologies and their ability to facilitate the work of quality managers. It also explains how FAI enables the founding of a stable manufacturing process that can deliver compliant parts of good quality that precisely meet customer requirements.<h2 id="isPasted">WHAT is First Article Inspection (FAI)? </h2>As its name suggests, FAI requires the complete inspection of parts before starting mass production. Primarily used on new products and designs, it ensures that the manufacturing process correctly interprets the design intent. It also provides customers with the documentation required to demonstrate compliance with the contract and specification requirements.<h2>WHY is FAI important? </h2>FAI aims to uncover manufacturing problems and catch errors before they become costly to fix. Consequently, it helps lower return rates and reduce costs associated with rework. It also contributes to improving customer satisfaction and increasing profitability.<h2>WHY is FAI challenging? </h2>Nevertheless, performing FAI on newly developed parts is challenging. Since all features must be measured and verified, it takes time&mdash;a lot of time&mdash;especially if the complete FAI is performed on the coordinate measuring machine (CMM). When the CMM is unavailable due to bottlenecks generated by controls on less important features, both part quality and production lead time are impacted negatively.The problem is that the more new parts there are (as it is often the case with new programs), the more FAIs there are to execute, and the more CMM time&mdash;and human resources to operate them&mdash;must be available, often in a short period of time.<h2>HOW to avoid bottlenecks at the CMM? </h2>The CMM is widely popular for FAI due to its high accuracy. In fact, the CMM has always been the reference measuring equipment for metrologists. This substantial demand comes with some drawbacks.The CMM must not only be available for the FAI of newly industrialized parts, but also it must be vacant to perform any type of inspection, particularly on critical dimensions. When performance criteria and tolerances are tight, metrologists prefer to control key features with the CMM. However, since it must be programmed and handled by specialized workers and is slow to operate, an <a href="https://www.creaform3d.com/blog/automated-quality-control-to-solve-cmm-issues/" target="_blank">accumulation of quality controls can create significant bottlenecks</a>, which delay the progress of the manufacturing process.Consequently, accessibility to the CMM is essential to guarantee the FAI of critical dimensions. To do so, redirecting less critical controls to another metrology instrument&mdash;simpler to learn and use&mdash;enable the QC team to avoid costly bottlenecks at the CMM, which remains the first stop for high-tolerance features.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1687339117436-cmm-3d-measurements-automotive-parts-1024x576.webp" style="width: 766px;" class="fr-fic fr-dib"><h2 id="isPasted">HOW to perform FAI in the context of globalization? </h2>Furthermore, FAI is now performed in the context of globalization. Products are now made of hundreds of components manufactured by a myriad of subcontractors and suppliers who are based in diverse locations around the world and use varied manufacturing processes. Once assembled, all components must fit together and align correctly to produce viable products free from defects that could distort their performance and ruin their efficiency.To illustrate that, let&rsquo;s consider a part designed by an automotive manufacturer in Europe. The numerical model is first sent to a subcontractor in Asia, who moulds and produces the part that will be sent and assembled on cars at a plant in South America. FAI is performed by the car manufacturer, who will attempt a first assembly and highlight the defects. Those incongruities will be referred to the subcontractor, who will correct his tooling before sending a new sample to the factory. Once again, components might not fit properly. Once more, the subcontractor will be asked to adjust the tooling. And so on, for a long round trip!If, however, there were ways to scan the part and send its digital model instead of physically sending it halfway around the world to measure it on the CMM, we would gain both efficiency and time. We could then proceed with a virtual assembly and virtually estimate the corrections without making parts physically travel around the world.<h2 id="isPasted">WHAT is the best alternative to the CMM? </h2>To improve, optimize, and accelerate FAI, manufacturers need an alternative measuring solution to support the CMM and provide QC professionals with the required accuracy, speed, portability, versatility, and simplicity.<ul style="list-style-type: circle;"><li>Accuracy: The measurement quality is essential to take on inspections previously assigned to the CMM. The alternative solution must provide accurate, high-resolution, and repeatable results regardless of the measurement setup quality. Measurements taken on the shop floor must also be insensitive to environmental instabilities. This means that, even if the part moves, vibrates, or oscillates during the inspection, the measured data is accurate and independent of a rigid measurement setup.</li><li>Speed: Since the CMM is slow to operate and takes time to program, the alternative solution must perform faster. It should also offer quick setup, real-time scans, and ready-to-use files, allowing QC professionals to accelerate FAI and save precious acquisition and analysis time, limiting production downtime.</li><li>&nbsp;Portability: As investigations on the tooling often occur directly on the production line, QC specialists must be equipped with a device capable of operating in various environmental conditions without affecting performance or impacting accuracy. Unlike the CMM, which must be kept in a controlled environment, the alternative measuring instrument must have the flexibility to be brought wherever the part is.</li><li>Simplicity: Finally, the alternative measuring instrument must be intuitive to learn, easier to use, and not require extensive programming time so that people with no special training, skills, or experience can operate it.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1687339214971-shaft-first-article-inspection_voestalpine-1024x683.webp" style="width: 766px;" class="fr-fic fr-dib">voestalpine engineer performs a first article inspection with the MetraSCAN 3D scanner&nbsp;<h2 id="isPasted">WHAT to expect from 3D scanning technology for FAI? </h2>Simply put, 3D scanning technology meets all these requirements and figures as the no.1 alternative solution to the CMM. Here is why:<h3>Accurate Shop-Floor Measurements </h3><a href="https://www.creaform3d.com/en/portable-3d-scanners" target="_blank">3D scanners</a> enable the QC team to go directly to the production floor and perform FAI at any time, thus eliminating wasted time and reducing the costs related to moving a defective part from the workshop to the CMM. Because they can measure parts in shop-floor environments&mdash;often influenced by temperature variations, vibrations, and oscillations&mdash;and can be moved around the production floor without impacting their accuracy, metrology-grade 3D scanners, such as the <a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan" target="_blank">Creaform MetraSCAN 3D</a>, are perfect for performing FAI on large and heavy parts and less critical features.<h3>Short Learning Curve </h3>With their user-friendly interface and ergonomic design, 3D scanning equipment have a short learning curve and are easy to use. With their faster setting and acquisition time, metrology-grade scanners, such as the <a href="https://www.creaform3d.com/en/portable-3d-scanner-handyscan-3d" target="_blank">HandySCAN 3D</a>, offer detailed analyses accessible to non-specialists in metrology. This accessibility and ease-of-use can limit delays in detecting and correcting the first parts&rsquo; defects.<h3>High Information Density for Detailed Analyses </h3>With 3D scanners, the QC team can now digitize complex shapes with a large number of data and without contact, allowing a more detailed analysis of FAI. Colormaps can quickly reveal where defects have appeared in the manufacturing process and which machine setting has created them. Information density accelerates problem-solving and decision-making in link with the first articles.Finally, 3D scanners are a huge step forward for FAI in the context of globalization. 3D scanning technology would even allow a purely virtual FAI in which the first physical parts would be compatible on the first try. The current technology has the capacity to enable it. It is simply a matter of integrating this new know-how into the manufacturer&rsquo;s training, culture, and mentality.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1687339238043-dashboard-first-article-inspection-vxelements-768x444.webp" style="width: 766px;" class="fr-fic fr-dib">Dashboard colormap result in VXinspect&nbsp;<h2 id="isPasted">3D Scanning for Improved, Optimized, and Accelerated First Article Inspection </h2>By adding a metrology-grade 3D scanner to the measuring instrument kit, delicate inspections of high-tolerance features can be assigned strictly to the CMM, while all remaining controls can be redirected to 3D scanning. This action not only ensures product quality through the global supply chain, but also improves diagnostics on reported quality issues and accelerates FAI, even if the company is struggling with limited resources and strict requirements.Furthermore, 3D scanning solutions optimize FAI by reducing the bottlenecks at the CMM and the time required for adjustments before mass production. Consequently, an optimized FAI enables quality control to quickly identify issues and promptly propose solutions. The first parts are then of higher quality, compatible with their assembly on the first try, and they meet customer requirements, thus generating greater satisfaction, sales, and profitability.

First article inspection (FAI) is a crucial step in the manufacturing process. The quality control (QC) team needs to optimize this phase of inspection in order to limit the back and forth between conception and fabrication. The QC team must not only correctly identify the defects, but also provide relevant data, measurements, and results for solving the identified problems.

How to Improve, Optimize, and Accelerate First Article Inspection

The main&mdash;if not the sole&mdash;purpose of reverse engineering is to gain knowledge about the design and development steps shrouded in the guise of a finished product. But what is backwards engineering if not a means to address practical issues such as machine downtime, part replacement, and maintenance or repair challenges?&nbsp;Implementing a <a href="https://www.creaform3d.com/en/applications/reverse-engineering-with-3d-scanning" target="_blank">reverse engineering</a> process is the starting point of a knowledge transmission model. In the present, it helps solve production problems; the main advantage is to create and safeguard knowledge for the future. Reverse engineered parts and products generate critical data and design information for the benefit of future product development endeavours, MRO, and spare part availability.Let&rsquo;s keep in mind that it&rsquo;s never too late to learn the ropes of something. That is why we put together this piece that acts as a step-by-step product reverse engineering guide for beginners.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686729673225-automotive-reverse-engineering-3d-scan-to-cad-1024x579.webp" style="width: 765px;" class="fr-fic fr-dib">Reverse engineering workflow (scan-to-CAD)&nbsp;<h2 id="isPasted">Here is How We Recommend to Begin with Product Reverse Engineering</h2><h3>The Product&mdash;Figure Out What Product You Want to Reverse Engineer</h3>Most of the time, this just goes without saying. Let&rsquo;s use our imagination and think of a loudspeaker manufacturer that produces pretty much all components of the speaker assembly itself, except for a few, namely the basket, made by Supplier A.Supplier A is acquired by Company X. Company X also manufactures the speaker basket, but the fit is not exactly right anymore. Then Company X goes bankrupt. In theory, all hope is gone. Meaning that no matter how hard you try to find an exact equivalent of the original part, you would have to bypass the knowledge transmission barrier inside both entities, be able to retrieve former designs that would have miraculously survived the acquisition and potential relocation, and much more, while making sure the whole process does not infringe patent rights and remains up to ISO standards.The original basket design was most likely lost in the acquisition process, and Company X&rsquo;s design is not up to the quality standards of the loudspeaker manufacturer.The solution? Let&rsquo;s reverse engineer the basket&mdash;and the entire loudspeaker, for that matter&mdash;and bring the entire production process in-house.<h3>The Research&mdash;Do Your Research and Make Sure You Understand How the Product Works</h3>You are no stranger to your product, but the simple fact that some of its components were manufactured by a third-party supplier reshuffles the whole deck. Understanding how the product works based on the individual role played by each part gives you complete control over what can be done in the now (e.g., go back in production phase), in the near future (e.g., product improvements), and in the long run (e.g., product development based on earlier designs).What are the implications of redesigning the component (i.e., the basket) via reverse engineering techniques? You need to gather as much information as possible: component fit and orientation, size, material, attachments and relation to other parts (e.g., electrical, mechanical, acoustic, etc.), compatibility, and so on. In fact, this process will probably make you rethink every single aspect of the product. What about this bracket? Let&rsquo;s model it too.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686729703135-metrascan3d-scanning-automotive-v8-intake-manifold-casting-lasers-1024x683.webp" style="width: 765px;" class="fr-fic fr-dib">Reverse engineering using 3D scanning enables automotive manufacturers to analyze, control and replicate existing parts for repairs or improvements.&nbsp;<h3 id="isPasted">The Plan&mdash;Create a Plan for How You Will Go About Reverse Engineering the Product</h3>Even though prolonged production downtime can put tremendous pressure on sales and shipping, the real enemy is the lack of scrutiny when thinking about how you will go about backwards engineering the loudspeaker.Although the ultimate goal is to get enough data to design and produce the basket-and-bracket assembly, there&rsquo;s not good reason to make haste. A carefully planned out disassembly of the product is in order. But that&rsquo;s not all: what reverse engineering methodology will you be using? Consultancy or in-house? Traditional measuring tools or <a href="https://www.creaform3d.com/en/portable-3d-scanners" target="_blank">3D scanning technology</a>? Where will you store the data? Who will be in charge? What will you do with the actual data? What is the endgame? Knowing the answers to most of these questions will prove invaluable for future product development and design endeavours.<h3>The Dissection&mdash;Begin Taking the Product Apart and Understanding How It Is Put Together</h3>Some say this is the fun part. The discovery and unearthing of product and component information is what makes this step a wonder comparable to archaeological findings. While this may have been somewhat of a stretch, taking the product apart and scanning its components reveal critical information that has gotten lost since the original design&mdash;due to broken data storage infrastructure, paper-to-electronic migration, and what not.The best way to go about is to inspect every nook and cranny, making sure nothing is left to chance. It&rsquo;s one part component specs, and one part how they are put together to form the product. There is always room for improvement in both cases&mdash;more on that later.Advanced technologies such as 3D scanning can be an important part of a product reverse engineering project. Dissecting the product is one thing, but getting the raw data as to the mechanical specifications, connections, positioning, friction points, load bearing, etc. brings the data to a whole other level, and 3D scanning is one efficient way of extracting these data.In our case, the critical information revolves around getting as much information as possible about the basket-and-bracket assembly. The best route is to scan former designs of the loudspeaker components, if available. Another approach would be to accurately measure everything that&rsquo;s in place to fill the void left by the basket assembly.<h3>The Model&mdash;Create a Model or Prototype of the Product</h3>You have the data. Now what?The now digitized product data acts as a blueprint of the components and product in their current state. Hence the name &ldquo;reverse engineering&rdquo;: You take a finished product and backtrack until you get to the preliminary design stage.The data can then be further inspected using specialized or generic software to reveal areas of improvement, recover mechanical specifications that may have gotten lost due to various reasons, secure component properties in a digital format that can be stored, shared, versioned and processed. This in turn allows engineers to remodel the components and product, and to build a prototype that takes the newly acquired information into consideration to solve initial challenges. As mentioned before, reverse engineering addresses the &ldquo;now&rdquo; problems, and gives you the flexibility to adapt to upcoming product designs, changes, improvements and developments.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686729728450-helmet-3d-scan-representation-1024x360.webp" style="width: 765px;" class="fr-fic fr-dib">Product development process: helmet 3D model&nbsp;<h3 id="isPasted">The Testing (and Refinement)&mdash;Test and Refine Your Model or Prototype</h3>This step speaks for itself; it basically means bringing the digital assembly into the practical world, testing it and making sure it meets all the expectations set out at the very start of the reverse engineering process.What are the indicators of quality? How does the product compare to former designs? What about the potential effects of harsh environmental conditions, vibrations, heat, pressure, repeated or intensive use replicated via cycle testing? Even if former version of the product didn&rsquo;t go through every single step of testing and refinement, this becomes the key step to making sure you (re)launch the production of a research-informed product, based on actionable data.Any discrepancy between the tested material and the expectations of the final product has to be brought to the drawing board for refinement purposes.<h3>The Findings&mdash;Put Together a Report or Presentation of Your Findings</h3>Since reverse engineering a component, assembly or product is no small feat, the whole process needs to be vetted at its starting point, and reviewed at the end. We cannot stress enough the importance of documenting everything from point A to point Z&mdash;failing to do so is a recipe for another blueprint or another dataset going astray, resulting in yet another production halt at the plant. Your report or presentation should include:<ul><li>Root cause</li><li>Intended use of the product at the end of the process</li><li>Reverse engineering methodology</li><li>Issues experienced</li><li>Areas for improvement</li><li>Suggestions, highlights, overall experience</li></ul>You are not expected to come up with a universal solution to all problems related to the product, but rather to act as a messenger in the continuous improvement process of said product. Plus, you may have unearthed additional smaller issues of which the solving method may require other team members or departments to jump in.In the end, the report or presentation should be an integral part of the knowledge transmission mechanism used by your company to prevent the loss of critical information.<h2>Continuous Improvement and Alternate Solutions</h2>Reverse engineering can be performed in various ways, and problems such as the loudspeaker basket unavailability can be solved with solutions other than reverse engineering. In the scope of things, an optimal product (re)development cycle requires strategy, a sense of delivery, value-adding tasks, great communication and minimal waste&mdash;and that is where traditional reverse engineering methods usually fail.Advanced methods and patented technologies such as 3D scanning instruments and software can be leveraged to save time and reallocate resources to value-added work. The faster the resolution, the better the chances of getting your production development process back on track.

The main—if not the sole—purpose of reverse engineering is to gain knowledge about the design and development steps shrouded in the guise of a finished product. But what is backwards engineering if not a means to address practical issues such as machine downtime, part replacement, and maintenance or repair challenges?

How to Get Started with Product Reverse Engineering?

In the last few decades, the world has seen a rapid transformation in how we live, work, and communicate, primarily due to technological advancements. This shift is commonly referred to as Industry 4.0, a term that represents the fourth industrial revolution. With Industry 4.0, we are witnessing the integration of new technologies such as artificial intelligence, robotics, the Internet of Things, and others into the manufacturing industry, making it smarter, more efficient, and more connected than ever.&nbsp;As Industry 4.0 continues to reshape the manufacturing industry, it is also reshaping the job market, creating a need for a new set of skills and competencies. This means that educators and institutions are responsible for preparing students for the demands of the future job market and ensuring they have the skills necessary to succeed in the Industry 4.0 era. In this article, we will explore the meaning of Industry 4.0, the skills required for it, and strategies for preparing students for this revolution.<h2 id="isPasted">What is Industry 4.0, and why prepare for it?</h2>Since its early days, the manufacturing industry has undergone multiple transformations thanks to technological advancements brought by the first, second, third, and now fourth industrial revolution, also known as Industry 4.0. From water and steam power generation to electricity and assembly lines to computers and automation, manufacturers worldwide are now adopting advanced technologies to streamline processes, increase efficiency, and reduce costs.While the technologies and applications of Industry 4.0 vary from manufacturer to manufacturer, here are the most common ones the fourth tech era operates through:<ol><li>Smart sensors and Internet of Things (IoT) devices that collect and analyze data in real-time to improve production processes, reduce waste, and prevent equipment breakdowns.</li><li>Robotics and automation systems that can perform repetitive tasks faster, with higher precision and quality, and with less risk of errors and accidents.</li><li>Artificial Intelligence (AI) and Machine Learning (ML)&nbsp;algorithms that can analyze large data sets and identify patterns, trends, and insights that can be used to optimize processes, reduce costs, and increase efficiency.</li><li>Additive manufacturing, also known as 3D printing, which allows manufacturers to produce complex parts and products with minimal waste and lead time, and greater customization and flexibility.</li><li>3D scanning technologies that allow manufacturers to create accurate and detailed digital replicas of physical objects and environments for quality control, inspection, and reverse engineering purposes.</li><li>Augmented and Virtual Reality (AR/VR)&nbsp;technologies that can improve training and maintenance processes by providing immersive and interactive experiences that simulate real-life scenarios and enhance learning and retention.</li><li>Cloud computing and Big Data analytics that enable manufacturers to store, process, and analyze large amounts of data from various sources, including sensors, machines, and humans, and use it to improve decision-making and innovation.</li><li>Cybersecurity solutions that protect sensitive data, intellectual property, and critical infrastructure from cyber threats and attacks.</li></ol>Despite the optimization and, in some cases, reduction of human resources due to the introduction of these technologies, a <a href="https://www.themanufacturinginstitute.org/research/2018-deloitte-and-the-manufacturing-institute-skills-gap-and-future-of-work-study/" target="_blank">recent study by Deloitte and the Manufacturing Institute states</a> that Industry 4.0 technologies are likely to create more jobs than they destroy. Even before the pandemic, one of the industry&rsquo;s significant challenges was a lack of skilled labor. According to the study, the manufacturing skills gap could result in 2.1 million unfilled jobs in 2030 in the U.S. alone and cost up to $1 trillion.To address the growing skill gap, it&rsquo;s crucial to provide relevant education and training not only to the existing workforce but also to students still choosing their path and considering manufacturing as one of their options. As Industry 4.0 technologies become more pervasive and influential, they will require a new set of skills and knowledge from future manufacturing workers to succeed in the job market. Some of the manufacturing jobs that will be common in 2030 don&rsquo;t exist yet, while the current ones may no longer be in place soon.That&rsquo;s why students must prepare for the new, constantly changing reality of Industry 4.0 to find meaningful and rewarding careers.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686124988543-industry-4-automotive-production-line-1024x576.jpeg" style="width: 766px;" class="fr-fic fr-dib">Automated robot arms on a car assembly line&nbsp;<h2 id="isPasted">Skills required for Industry 4.0</h2>As Industry 4.0 continues to evolve and reshape the manufacturing industry, so do the new jobs and career pathways, creating a demand for new skills and competencies. Robots and computers already perform some of the routine, mundane, and repetitive tasks, allowing workers to focus more on strategic decision-making, problem-solving, and communication activities. On the other hand, educational systems are having a hard time keeping up with all the technological changes happening in the industry. As a result, there is still a massive gap between the demand for skilled workers and what students are learning.To succeed in the Industry 4.0 era, students must acquire skills that combine technical, cognitive, and socio-emotional abilities. These skills can vary depending on the industry, job role, and level of responsibility, but some of the must-haves are:<ol><li>Digital literacy: using digital tools and platforms to communicate, collaborate, and solve problems. Examples include using social media, email, instant messaging, video conferencing, cloud storage, and project management software.</li><li>Data analysis: the ability to collect, process, interpret, and visualize data from various sources and formats to gain insights, make decisions, and improve performance. Examples include using Excel, Tableau, Python, or R to analyze sales data, customer feedback, or production metrics.</li><li>Automation and robotics: the ability to design, program, operate, and maintain automated and robotic systems that can perform repetitive, hazardous, or complex tasks. Examples include using Arduino, Raspberry Pi, or PLCs to control a robotic arm, conveyor belt, 3D printer, or 3D scanner.</li><li>Artificial intelligence and machine learning: the ability to understand, apply, and develop algorithms and models to learn from data, make predictions, and optimize processes. Examples include using neural networks, decision trees, or reinforcement learning to create chatbots, predictive maintenance systems, or supply chain optimization tools.</li><li>Creativity and innovation: the ability to generate, evaluate, and implement new ideas, products, or processes to create value for customers, stakeholders, and society. Examples include designing a new product line, developing a marketing campaign, or improving a production process to reduce waste or energy consumption.</li><li>Critical thinking and problem-solving: the ability to analyze, evaluate, and solve complex and ambiguous problems by applying logic, evidence, and creativity. Examples include troubleshooting a machine malfunction, resolving a customer complaint, or identifying the root cause of a quality issue.</li><li>Communication and collaboration: the ability to express ideas, listen actively, and work effectively with others from diverse backgrounds, cultures, and perspectives. Examples include giving a presentation, participating in a team project, or resolving a conflict with a colleague.</li></ol>Industry 4.0 opens up many challenging and exciting opportunities for students. It requires a deep technological skillset and soft skills, such as creativity, problem-solving, communication, and collaboration, that are essential for innovation and competitiveness. Students who can develop and apply these skills in the <a href="https://www.creaform3d.com/blog/webinars/overcome-industry-40-inspection-challenges/" target="_blank">context of Industry 4.0</a> are likely to be in high demand by employers and have more career advancement and personal growth opportunities.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686125013805-student-engineer-virtual-reality-1024x576.jpeg" style="width: 766px;" class="fr-fic fr-dib">The student engineer is utilizing virtual reality software to advance his project.&nbsp;<h2 id="isPasted">How to prepare students for Industry 4.0</h2>Preparing students for Industry 4.0 requires a joint and proactive approach from educators and institutions. Here are some strategies for effectively preparing students for the demands of the future manufacturing job market:<h3>Integrate Industry 4.0 technologies in the classroom</h3>To keep students up-to-date and give them hands-on experience with all the recent advanced technologies used in manufacturing, educators can incorporate Industry 4.0 technologies directly into the classroom.This could include using virtual reality simulations to teach complex concepts or incorporating robotics and automation into the curriculum. It can also involve setting up in-house maker spaces where students can learn to operate various hardware and software tools, such as 3D printers, <a href="https://www.creaform3d.com/en/portable-3d-scanners" target="_blank">3D scanners</a>, laser cutters, CNC machines, CAD software, and 3D sculpting software. Such places can expose students to the world of high-tech technologies and give them a perspective on what their day-to-day at work can look like. Having experience operating a 3D scanner or using <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" target="_blank">CAD software</a> can enrich their learning experience and give them an edge over others when looking for that dream job.One example of such an initiative is the <a href="https://www.creaform3d.com/blog/3d-scanning-in-a-design-and-innovation-lab/" target="_blank">Design and Innovation Makerspace</a> in the College of Engineering at the University of Wisconsin&ndash;Madison. Launched in 2017 after the overhaul of an old engineering library, the Makerspace offers their students access to a broad range of very impressive high-tech equipment, including 3D printers, 3D scanners, CNC routers, laser cutters, drones, VR/AR headsets, and more. Largely student-run, Makerspace strives to empower students by creating a community immersed in emerging technologies and focused on creating innovative products. For instance, one of the most popular and versatile pieces of equipment used by students from various faculties is Creaform Academia&rsquo;s portable 3D scanners. With them, students can easily digitize any physical object, whether an auto part or a historical artifact, and bring it into the digital world.If setting up such a space is out of your budget, it&rsquo;s still possible to expose students to all the latest tools by partnering with a local maker space or a science center. Such places can provide access to high-tech equipment and organize full training for teachers, so they can later introduce such classes into their curricula.Traditional shop classes can no longer sustain or prepare students for the growing industry demands for highly skilled workers, which is why integrating Industry 4.0 technologies, such as additive manufacturing, robotics, and coding, into the schools&rsquo; programs is necessary.<iframe width="640" height="360" src="https://www.youtube.com/embed/P6BvNB66V7Q?&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><h3 id="isPasted">Collaborate&nbsp;with industry partners and professionals</h3>Partnering with local businesses and industry leaders can provide students with valuable opportunities to get real-world experience, learn about the latest trends and technologies, and gain insights into the skills and competencies required for Industry 4.0 jobs. To achieve this, educators can collaborate with industry partners and professionals in multiple ways.For instance, they can invite industry experts as guest lecturers to teach hands-on classes or workshops on Industry 4.0-related subjects, where students can learn some practical skills, or they can share their career journey and answer questions that students might have.Another way is to organize regular tours of the factories and production facilities, where students can observe some of the manufacturing processes and what the daily life of a manufacturing worker can look like. Finally, educators can provide students with opportunities to participate in internships or apprenticeships with industry partners to get real-life experience that will help them in their future career paths.Regardless of the format, working with industry leaders can give schools the latest industry insights and knowledge they won&rsquo;t get anywhere else.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686125054147-peel-3-application-EDU-1-1024x683.webp" style="width: 766px;" class="fr-fic fr-dib">Using the Peel 3 3D scanner, the teacher imparts knowledge to his students about the essential concepts of 3D scanning.&nbsp;<h3 id="isPasted">Provide mentorship, coaching, and career guidance</h3>Navigating the complex and dynamic Industry 4.0 job market can be overwhelming, especially if the two factors above haven&rsquo;t yet been introduced into the school system. Despite all the technological breakthroughs and innovations introduced in recent years, the manufacturing industry is still publicly perceived as dangerous, dirty, and having low job security.To change that perception and create a pipeline of qualified applicants, educators must provide mentorship, coaching, and career guidance for students who aspire to pursue a career in Industry 4.0. For example, schools can create mentoring programs that connect students with experienced professionals who can share their knowledge, skills, and networks and provide feedback, advice, and support. Schools can also offer career counseling and job placement services that help students identify their strengths, interests, and goals and match them with relevant job opportunities and employers.They can also highlight the opportunities, rewards, and benefits of pursuing a career in this field by showing students the salary upside of working in manufacturing. Give them real-world examples of what they can expect to make if they have certain skills and certifications. One way to do so is to create credits that can be used toward certifications when students graduate. Let students accumulate credits or work toward certifications they can take when they graduate. With these in hand, they can either go on to further study or get a job.<h2>Conclusion</h2>As we see, Industry 4.0 keeps transforming the manufacturing industry, creating new opportunities and challenges for students preparing to enter the workforce. To ensure that the next generation of workers is ready for these opportunities and challenges, we must prepare students for Industry 4.0 jobs, update the curriculum to focus on emerging technologies and industry trends, and establish partnerships between educational institutions and industry leaders. By working together, we can bridge the skills gap and ensure that the manufacturing industry has access to the talent it needs to continue to grow and innovate.

In an engineering lab, students learn how to 3D scan objects in real-time.

Learn how to prepare students for the demands of the future job market and ensure they have the skills necessary to succeed in the Industry 4.0 era.

Prepare Your Students for Industry 4.0

<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1684935422834-Picture-1_HYVA-Cover-Pictures.webp" style="width: 766px;" class="fr-fic fr-dib">Founded in 1979 in The Netherlands, the <a href="https://www.hyva.com/en/" target="_blank">HYVA CAPITAL EQUIPMENT FACTORY</a> (HCE) is a leading global provider of innovative and highly efficient transport solutions for commercial vehicles and environmental service industries. The company is committed to the development, production, marketing and distribution of components used in hydraulic loading and unloading systems on trucks and trailers. Its products are used worldwide, across a wide range of sectors including transport, construction, mining, materials handling and environmental services providers.HYVA&rsquo;s portfolio comprises of hydraulics (cylinders and tipping gear), container handling systems (hook and skip loaders), waste handling (transfer stations, compactors and refuse collection bodies), floors (horizontal unloading/loading floors) and cranes (fixed and rolling). &nbsp;These products are designed and marketed under several well-respected brands, such as Hyva, Kennis, F.lli Ferrari and Amco Veba. Hyva is also a distributor of high value components.HYVA&rsquo;s Italian factory recently invested in a <a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan" target="_blank">MetraSCAN|BLACK scanner</a> from Creaform as they wanted to reduce their inspection times and wanted to control large parts like cranes chassis (260 x 140 x 80 cm), booms (200 cm), extensions (180 cm) and hookloaders subframe (800 cm).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1684935442694-2023-05-09-10_45_57-2023_01_20_Case-Study_HYVA_EN_FINAL_rev_DC.docx-Word-1024x306.webp" style="width: 766px;" class="fr-fic fr-dib">Prior to that purchase, the systems used for quality control tasks required metrology experts, often multiple measurement instruments and a long inspection time. These aspects prompted the search for a fast and easy-to-use 3D solution.Compared to other metrology solutions on the market, Creaform&rsquo;s scanner proved itself to be a major improvement due to its quick and easy data acquisition and the capacity to measure intricate details. Other decisive factors were the possibility to measure bulky components directly in the production environment independently of vibrations, as well as the reduction of measurement errors, the reduction of inspection times and the accuracy of the instrument.<h2>Quality check of supplier parts</h2>Today, the MetraSCAN 3D scanner, together with the <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms" target="_blank">inspection software VXelements</a>, is used at HYVA to quality check incoming components from suppliers. In this instance, for example, a crane extension had to be inspected to confirm whether or not the component was conforming to the drawing.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1684935463141-2023-05-09-10_49_04-2023_01_20_Case-Study_HYVA_EN_FINAL_rev_DC.docx-Word-1024x341.webp" style="width: 766px;" class="fr-fic fr-dib">Digitization of a crane extension with the MetraSCAN 3D at HYVA and real-time visualization of the scan in VXelements&nbsp;The scan displays in real time in the VXelements software, which combines acquisition and application modules into the same simple, easy-to-use interface, providing a complete solution rather than a simple measurement device only. This way, deviations can be detected immediately.Of course, this specific project could have been carried out with traditional measurement methods (like measurements arms), but it would have taken much longer, actually three times more time. &nbsp;In general, with the 3D scanner, HCE reduced significantly its inspection time, which enabled HYVA to increase the number of components checked daily and increase the quality of their supplier.<h3>What must be mentioned &hellip;</h3>According to HYVA, the MetraSCAN 3D scanner is easy to use and its manipulation intuitive. Also, it is light and portable, which means it can be used wherever it&rsquo;s needed. The&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/creaform-product-overview" target="_blank">Creaform technology</a> enables them to have a wide scan without limits of shapes and surfaces and allows total freedom of movement. At HCE, the scanner is used for all incoming controls, both for specific projects and for routine control activities. It allows the company to have precise, fast measurements and the report is generated automatically.&ldquo;Creaform&rsquo;s 3D scanner allows us to optimize the use of resources dedicated to inspections both in terms of timing and number of checks performed. It is a precise and easy to use tool&rdquo;, states Stefano Lillo, LOB Quality Manager Cranes &amp; HCE Plant Quality Manager at HYVA.

Leading global transport solutions provider reduces its inspection times with the Creaform 3D scanner

3D Scans Without Limits of Shapes and Surfaces

Over the last few decades, reverse engineering has become an essential part of product design and production processes used by manufacturers all over the globe. From aerospace to automotive to everyday consumer goods, industrial engineers and product designers rely on&nbsp;<a href="https://www.creaform3d.com/blog/what-is-reverse-engineering/" target="_blank">reverse engineering</a> when replicating a legacy part without documentation or drawings, analyzing and deconstructing a competitive product, or modifying and improving an existing one. As technology improves, so do the hardware and software utilized to digitize physical parts or assemblies into reliable, accurate, and solid computer-aided design (CAD) models. New metrology sensors, more capable software enabled by faster and cheaper computing, and advances in AI are shaping the future of reverse engineering, opening up more potential applications and making it accessible to a broader range of professionals.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg0NDAzNjYzODY1LVRyYW5zZmVydC10by1DQUQtMTAyNHg1ODAud2VicCIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 766px;" class="fr-fic fr-dib">With all that in mind, let&rsquo;s see what trends will impact the state of reverse engineering in the coming years.&nbsp;<h2 id="isPasted">What are the top three trends in reverse engineering for 2023?</h2><h3>Reverse Engineering Trend #1: Rapid Prototyping</h3>Most products manufactured today go through multiple iterations before they roll off the assembly line. This iterative workflow is called &ldquo;rapid&rdquo; or &ldquo;fast&rdquo; prototyping and refers to techniques used to develop physical prototypes or models of a product or component as quickly as possible to emulate a final product design. In recent years, rapid prototyping has become the go-to method for manufacturers to test and validate design ideas before committing to mass production, lowering the risk of costly mistakes and delays.<a href="https://www.creaform3d.com/en/applications/reverse-engineering-with-3d-scanning" target="_blank">Reverse engineering</a> plays a critical role in this workflow, enabling companies to create digital models of existing products or parts that can be used as the basis for <a href="https://www.creaform3d.com/en/applications/consumer-products/rapid-prototyping-when-accurately-converting-clay-models-cad-files" target="_blank">rapid prototyping</a>. For example, automotive companies use 3D scanners to capture manufactured parts that fit into an assembly and reverse engineer them as a baseline for new parts instead of starting with the original CAD files. This not only accelerates the product development process but also improves the quality of the final product. The same goes for design studios constantly creating new product designs, be it something as simple as a new toothbrush model or an MRI machine. Starting from a scan rather than from scratch can save tons of time.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg0NDAzNjkxMzU5LUF1dG9tb3RpdmVfUERldl9IYW5keVNDQU4tQkxBQ0tfaHl1bmRhaV8xLTEwMjR4NTc3LndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">With 3D scanners and&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" target="_blank">reverse engineering software</a> becoming smarter, cheaper, and more accessible to non-technical personnel, rapid prototyping will become even more widespread across various domains. Instead of relying on traditional and often slow manufacturing processes such as CNC machining or injection molding, design professionals will opt for light- or laser-based scanning technologies, CAD software, and additive manufacturing to develop accurate, feature-rich prototypes on the fly. Using handheld,&nbsp;<a href="https://www.creaform3d.com/en/portable-3d-scanners" target="_blank">portable 3D scanners</a>, they can capture any product or part right on the shop floor and upload the final 3D model into CAD software for further virtual testing and analysis or into 3D printing software to create a rapid, high-fidelity prototype.<h3>Reverse Engineering Trend #2: Additive Manufacturing</h3>The second trend shaping reverse engineering is the increased use of additive manufacturing. Also known as &ldquo;additive layer manufacturing&rdquo; or, in some cases, as 3D printing, additive manufacturing is an advanced fabrication process of building three-dimensional parts by joining material layer by layer from a CAD file. Since the 1980s, additive manufacturing technologies have been rapidly developing. Recent advances in hardware, materials, and software have made additive manufacturing accessible to a broader range of businesses, allowing more and more companies to use tools previously limited to a few high-tech industries.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg0NDAzNzE5NjUxLW1ldHJhc2NhbjNkLUxpbmNvbG4tRWxlY3RyaWMtQWRkaXRpdmUtbWFudWZhY3R1cmluZy02LXNjYWxlZC53ZWJwIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">All these could not help but affect the scope of reverse engineering. With far more affordable professional 3D printers, an improving cost-per-part ratio, and the introduction of new printing materials, more businesses can afford additive manufacturing and reverse engineer a more comprehensive range of products cost-effectively.<a href="https://www.creaform3d.com/en/solutions/3d-scanning-improve-quality-control-additive-manufacturing-processes-large-parts-0" target="_blank">Many companies already introduce additive manufacturing</a> as part of their reverse engineering routine. For instance, shoe manufacturers use portable 3D measurement technologies to capture the older models, modify them, and 3D print them to see how the new model will look and act in motion before moving on to the production stage.&nbsp;<a href="https://www.creaform3d.com/blog/vintage-car-restoration-data-acquisition-for-the-creation-of-replicas-and-spare-parts/" target="_blank">Automotive restoration shops</a> are introducing additive manufacturing for prototyping and creating working parts for vehicles to replace missing ones. Some hospitals, including veterinary ones, integrate 3D printers to develop custom orthotic and prosthetic devices based on reverse-engineered patient scan data.As both 3D printing and scanning technologies improve, so do reverse engineering and printing software, and more manufacturers will leverage those technologies to streamline their reverse engineering tasks.<h2>Reverse Engineering Trend #3: Virtualization</h2>Another emerging approach that manufacturers are widely integrating into their workflows, along with reverse engineering, is virtualization. Sometimes those two terms are used as synonyms for describing a process of creating a digital model of a physical object, also called a digital twin. However, virtualization goes further and involves analyzing and optimizing a product&rsquo;s design in a virtual space without physical prototypes and simulating how a product will perform under different operating conditions.Virtualization is useful for engineering, design, and manufacturing processes, as it enables users to interact with virtual prototypes in a lifelike manner before they move into production. VR and AR also make it easier to test the <a href="https://www.creaform3d.com/blog/leveraging-3d-scanning-3d-printing-and-artificial-intelligence-in-product-development/" target="_blank">ergonomics of products</a> before they are made and make changes in virtual environments. In addition, virtual spaces provide workers with an immersive learning experience, such as virtual tours of factories or virtual demonstrations of how to operate machinery. Lastly, different teams can share and access virtual models from different places. This makes it easier for people to collaborate and communicate during product development.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg0NDAzNzM3OTA4LVZpcnR1YWxpemF0aW9uLUh5cGVyZ2FuaWNUZWNobm9sb2dpZXNfRnJvbnRfQWx0ZXJuYXRlLTEwMjR4NTQ0LndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">Recent advances in AR and VR, artificial intelligence, and machine learning make virtualization more accessible for a broader range of manufacturers and industries. Virtualization is mostly used in high-tech fields like aerospace, automotive, and manufacturing, but it is becoming more common in construction, architecture, and entertainment. Virtualization is used, for example, to simulate how a building will act in different weather conditions or to make digital sets for movies and TV shows.COVID-19 and the general trend toward remote work have also made it easier to use virtualization for things like modeling, controlling shop floor simulation processes, planning production, testing, and verifying.How will this impact reverse engineering, you&rsquo;ll ask? Since virtualization is becoming more prevalent, it will require creating virtual models of products and spaces that are more realistic than traditional 3D models designed from scratch. This, in turn, will require high-precision scanning technology and reverse engineering software to create clean, high-quality, and solid 3D CAD models that can later be used in a virtual setup.Recommended reading:&nbsp;<a href="https://www.wevolver.com/article/explore.3d.scanners.and.3d.measurement.technologies" rel="noopener noreferrer" target="_blank">Explore 3d scanners and 3d measurement technologies</a>As virtualization becomes more popular, 3D measurement technologies will become more common. This means that not only technical staff but also other employees will need to learn how to use them. Since both scanners and software are becoming more affordable and operator-friendly, more and more people can use them in a working environment.

Over the last few decades, reverse engineering has become an essential part of product design and production processes used by manufacturers all over the globe. From aerospace to automotive to everyday consumer goods, industrial engineers and product designers rely on reverse engineering when replicating a legacy part without documentation or drawings, analyzing and deconstructing a competitive product, or modifying and improving an existing one.

What is the Future of Reverse Engineering?

Engineer scanning a helicopter engine with a metrology-grade 3D scanner.

You have been tasked with buying a 3D scanner. The only problem is figuring out where to start your search. You know what 3D scanning is but don’t know enough about it to make an informed choice.

What Is the Best 3D Scanner?

Partner:<a href="https://www.arotec-robotik.de/home.html" target="_blank">AROTEC Automation und Robotik GmbH</a>Challenge:Unloading or depalletizing rims from an EWPS pallet is a physically demanding activity for humans. The customer &ndash; an automobile manufacturer &ndash; was therefore looking for an automation solution that would solve this challenge. AROTEC developed a unique solution &ndash; a robotic rim depalletizer.Solution:<a href="https://www.photoneo.com/phoxi-3d-scanner/" target="_blank">PhoXi 3D Scanner XL</a>AROTEC developed a one-of-a-kind automation solution for robot-assisted rim depalletizing &ndash; RimDepal.The robotic rim depalletizer RimDepal consists of two industrial robots &ndash; each with a specialized end-of-arm tool, a 3D measuring unit, and a special separation station.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1683185581415-Arotec_Rim+depalletization_Social+media.png" style="width: 766px;" class="fr-fic fr-dib">Picture: Final plant installation An EWPS composite is conveyed into the robotic cell. As soon as the EWPS composite reaches the depalletizing place, it is detected/captured for the first time by the Photoneo PhoXi 3D Scanner, model XL.&nbsp;Based on the sensor data, AROTEC&rsquo;s software DEPAL@Rim determines the exact pose of the EWPS end frame and calculates the corresponding collision-free robot trajectory. One of the robots picks up the EWPS end frame and places it in a storage place.&nbsp;Immediately afterwards, the second robot picks up the plastic layer pad, together with the protective films/fleeces, and puts it into the separation station.&nbsp;After separation, the robot sets the layer pad down on a storage place. Next, the EWPS composite is detected/captured again. Based on the sensor data, DEPAL@Rim now determines the poses of the rims and calculates one or more collision-free robot trajectories with which the robot can grab up to two rims simultaneously and transfer them to the conveyor belt.&nbsp;This depalletizing sequence repeats until the last rim has been depalletized. Finally, a robot grabs the EWPS end frame and the layer pads and inserts them both into the EWPS base frame. The unit is then transported and strapped with a plastic strap.According to AROTEC, they are not aware of any similar automation solution that achieves rim depalletizing with the flexibility and performance of AROTEC&rsquo;s RimDepal solution.&nbsp;This is possible thanks to the Photoneo 3D vision sensor, the flexible end effectors/end-of-arm tools, and the separation station, which can process all common intermediate layers (sizes) with film, foam film, and fleeces.AROTEC&rsquo;s innovative robotic solution RimDepal can depalletize rims from 14&Prime;-24&Prime; in a multiple grip from all common EWPS pallets &ndash; even mixed types. The exact position of the rims is precisely determined by the Photoneo PhoXi 3D Scanner XL. Protective films and fleeces are separated from the plastic intermediate layers in a separation station specially developed for this purpose.&nbsp;Discussion:The PhoXi 3D Scanner XL is one of a few 3D vision sensors available on the market with such a large detection range. The sensor copes well even with shiny black rims. In addition, the price-performance ratio of the scanner is very good.The capture of the EWPS composite: Based on the point cloud/sensor data, AROTEC&rsquo;s proprietary object recognition software DEPALGO@Rim is able to precisely locate the EWPS end frame, the plastic layer pads, and the rims.&nbsp;To AROTEC&rsquo;s knowledge, this automation solution is the world&rsquo;s first system that allows a robot to fully automatically destack/depalletize all common EWPS pallets (consisting of an end frame, layer pads with protective films/fleeces, and rims) without any setup.&nbsp;After all rims have been depalletized, the layer pads and the EWPS end frame are reinserted into the EWPS base frame. The separation of foils/fleeces is also done automatically in a specially developed separation station.The robotic solution improves ergonomics and ensures cost-reduction.The video above shows the plant setup at AROTEC.Would you like to discuss your project with Photoneo? <a href="https://www.photoneo.com/contact-us/" rel="noopener noreferrer" target="_blank">Contact them here</a>.

Automated depalletization of rims using Photoneo 3D vision

RimDepal by AROTEC allows robots to fully automatically depalletize all common EWPS pallets with unprecedented performance and flexibility. The solution harnesses the power of Photoneo 3D vision, which can cover a large scanning area and provide high-quality 3D data even for shiny black materials.

Automated rim depalletizing

The military and defense sectors are undergoing an unprecedented transformation as military bases around the world adopt 3D scanning and additive manufacturing technologies for a wide range of applications. That includes maintenance, repair, and overhaul (MRO) processes, damage assessments and reverse engineering of parts, to name a few.This transformation is helping military and defense organizations drastically reduce their reliance on bogged-down supply chains and a tight labor market&mdash;all while maximizing efficiency and reducing costs.The&nbsp;<a href="https://www.travis.af.mil/" target="_blank">Travis Air Force Base</a> in California, for example, uses&nbsp;<a href="https://www.creaform3d.com/en/handyscan-3d-silver-series-professional-3d/technical-specifications" target="_blank">Creaform&rsquo;s HandySCAN 700, now known as the HandySCAN 700&trade;|Elite</a>, along with two additive manufacturing units, to scan components right on shop floors and then 3D print polymer and metal replacement parts.Interviewed by Airman Magazine, Josua Orr, an aircraft mechanic for the 60th Aircraft Maintenance Squadron, explains how these new solutions have saved the team lots of manpower hours and production costs compared with traditional methods. The team is also more efficient in carrying out damage inspections with the 3D scanner to save time and reduce human error, compared with conventional tape measures and pit depth gauges.<iframe width="640" height="360" src="https://www.youtube.com/embed/RAwYS4qIEVE?&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>Tim Osborn, Ph.D., Group Leader of&nbsp;<a href="https://udayton.edu/udri/capabilities/advanced_manufacturing/additive_manufacturing/am_technology_development.php" target="_blank">Additive Manufacturing technology Development at the University of Dayton Research Institute</a>, is pushing the technology envelope further with 3D scanning and 3D printing through the Maturation of Advanced Manufacturing for Low-Cost Sustainment (MAMLS), an America Makes initiative.His teams use <a href="https://www.creaform3d.com/en/portable-3d-scanner-handyscan-3d" target="_blank">HandySCAN 3D</a> to scan aging aircraft components for just-in-time inventory management. The 3D scans are imported into SolidWorks to enable the production of highly accurate 3D CAD models, which can then be sent to 3D printers for immediate production within a few hours. This attests to the tremendous value 3D scanning brings for reshoring production and improving manufacturing agility.<iframe width="640" height="360" src="https://www.youtube.com/embed/_HwDnxAZi4s?&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><a href="https://www.aircorpsaviation.com/" target="_blank">AirCorps Aviation</a>, situated in Bemidji, Minnesota, offers end-to-end restoration, contract manufacturing, and FAA-certified repair services. The company decided to broaden its capabilities to include 3D scanners and additive manufacturing for its aerospace customers.The business acquired Creaform technology to scan various aircraft components. The team can create fabrication-ready CAD models directly from the scan data using the scanner&rsquo;s SCAN-to-CAD functionalities. The company also uses the 3D scanners to conduct inspections for as-built conditions and engineering design data.<iframe width="640" height="360" src="https://www.youtube.com/embed/tjJWRs3VgO8?&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>

The military and defense sectors are undergoing an unprecedented transformation as military bases around the world adopt 3D scanning and additive manufacturing technologies for a wide range of applications. That includes maintenance, repair, and overhaul (MRO) processes, damage assessments and reverse engineering of parts, to name a few.

3D Scanning, 3D Printing and the New Production Imperative in Military and Defense Applications

The painstaking work of scribes in the Middle Ages, patiently copying out works of literature for the great libraries of the monastic orders, is a relic of a bygone age. Today, the multifunction printer is a staple feature of all offices and many homes; it has never been easier to create documents or designs with software such as Microsoft Word or Autodesk&rsquo;s AutoCAD&reg; tool, and to print them on demand.&nbsp;It&rsquo;s remarkable, then, that much of the construction industry still uses a technique more akin to the monastic scribe&rsquo;s than to the technology of the 21st century. When an architect&rsquo;s drawing of a building&rsquo;s floorplan needs to be marked on the floor of the job site, skilled surveyors are normally employed to take measurements, plot the lines and apply markings to the floor by hand. Like the scribe&rsquo;s handicraft, it is painstaking, skilled, time-consuming and expensive work. And even when performed by professionals, the work is prone to mistakes caused by human error.&nbsp;HP, the world&rsquo;s largest manufacturer of printers, saw in this process an opportunity to increase the efficiency and dramatically improve the productivity of this layout process. Its vision was for a combination of its printing expertise with the latest mobile robotics technology. The result was the SitePrint robotic layout solution, the world&rsquo;s first automated floorplan mobile printer for the construction industry.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1679475003239-HP+SitePrint+-+Lifestyle+image+29.jpg" style="width: 300px;" class="fr-fic fr-dib">And inside SitePrint is a sophisticated Xsens MTi motion sensor from Movella which keeps the vehicle pointing in the right direction, and ensures that ink is deposited accurately on the floor.&nbsp;Laser guidance technology&nbsp;The SitePrint product gives construction companies a fast and easy way to automate layout because it integrates with tools and systems that are already used in most large construction projects today. Before arriving at a job site, a surveyor will download to the SitePrint software a digital plan of the floor from AutoCAD or other familiar design tools. On site, the surveyor connects the SitePrint vehicle to a robotic total station (a standard optical surveying tool) via Bluetooth&reg; or Wi-Fi&reg; wireless. The total station&rsquo;s laser triangulation system continuously maps the position of the SitePrint vehicle via its tracking prism, and supplies real-time x,y co-ordinates to the vehicle over the wireless communications link.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1679475030463-HP+SitePrint+-+Lifestyle+image+51.jpg" style="width: 300px;" class="fr-fic fr-dib">The vehicle compares these x,y co-ordinates with the layout &lsquo;map&rsquo; downloaded from AutoCAD to work out where to print markings on the floor. The HP ink technology enables durable layouts to be printed on any compacted or flat surface, including rough concrete, brickwork, timber or screed.&nbsp;HP says that the printer&rsquo;s markings are accurate to 3mm. Enabling this high accuracy, the SitePrint vehicle features an <a href="https://www.movella.com/products/sensor-modules/xsens-mti-3-ahrs" rel="noopener noreferrer" target="_blank">Xsens MTi-3</a>, a self-contained AHRS (attitude and heading reference system) module from Movella. This robust, miniature motion sensor provides heading data &ndash; showing the direction in which the vehicle is moving &ndash; and gyroscope outputs, to give a precise measurement of inclination.&nbsp;The reliability of the heading data is critically important: the total station link ensures that the SitePrint vehicle&rsquo;s position is known accurately. But to print a line accurately on the floor, it must also be moving in the right direction. Here, the industry-best magnetic immunity of the <a href="https://www.movella.com/products/sensor-modules#selector" rel="noopener noreferrer" target="_blank">MTi family</a> of motion sensors is valuable. Construction sites are full of magnetic interference caused by the presence of large metal objects such as steel joists, electrical cabling and pipework. The MTi-3 is supported by Movella&rsquo;s unique Magnetic Field Mapper, a magnetic calibration tool supplied to developers as a software development kit (SDK) or as a PC-based application. The Magnetic Field Mapper enabled HP to optimize the SitePrint navigation system for immunity to the type of magnetic interferences generated by the SitePrint itself.The MTi-3&rsquo;s gyroscope outputs also accurately gauge the tilt of the vehicle as it passes over surfaces with any kind of slope. The accurate tilt and pan measurements from the MTi-3 ensure that the SitePrint product prints its marks as accurately when tilted as it does when perpendicular.&nbsp;Automation produces big productivity gainsAccording to HP product manager Pau Sole, the SitePrint product is set to become the new standard way to perform the layout function in modern construction sites. He says: &lsquo;Automation has increased productivity in many areas of commercial life, but in the construction industry, technology has not had such a profound effect before now. That&rsquo;s why the SitePrint product is such a breakthrough. Now layout can be completed on-site as much as 10 times faster than before. It also only requires a single surveyor to periodically monitor the operation of the SitePrint vehicle, rather than two surveyors working full-time on manual layout.&nbsp;&lsquo;It&rsquo;s a game changer for the construction industry, not only because of the productivity and speed improvements. Equally important is the reduced reliance on skilled staff. Surveyors who are qualified to do layout are scarce, and lack of availability of layout surveyors is often a bottleneck that holds up progress on job sites. With the SitePrint technology, construction companies can halve their requirement for surveyors, and free up these skilled professionals to perform other valuable work that cannot so easily be automated.&rsquo;Robust, reliable motion sensor for tough building jobsAs the SitePrint product takes on layout tasks in more and more construction sites, it will be exposed to the typical treatment meted out by the building industry. Pau Sole says that the SitePrint design is rugged, to cope with shocks and vibration, and to operate reliably in job sites that are dusty and dirty, and might be extremely hot or cold.&nbsp;The SitePrint layout solution can handle it all &ndash; and with&nbsp;<a href="https://www.movella.com/products/sensor-modules/xsens-mti-3-ahrs" rel="noopener noreferrer" target="_blank">MTi-3</a> motion data in support, it maintains ultra-high accuracy at all times.&nbsp;

with Xsens MTi-3

HP's mobile robot printer automates layout at construction sites

Partner:<a href="https://rossum.sk/en/" target="_blank">Rossum Integration s.r.o.</a>Challenge:The customer needed a solution for automated contamination control of crates and their filling with a material. Before, this task was performed manually.Empty crates entering the filling process can be contaminated by candy products previously stored in the crates. Improper control of the crates may lead to material mixing and contamination so the products would be categorized as NG (&ldquo;not good&rdquo;).The crates can be filled with products of various shapes, sizes, and colors. In addition to this variation, the crates itself can have a bulging bottom or broken plastic ribs. All these variables called for a complex automation solution.Solution:<a href="https://www.photoneo.com/phoxi-3d-scanner" target="_blank">PhoXi 3D Scanner M&nbsp;</a>The deployed automation solution consists of a PhoXi 3D Scanner from Photoneo, PEKAT VISION software, control system Simatic S7-1500, pneumatic system Festo, automatic weighing system Mettler Toledo, and a vibrating platform for uniform material distribution.The contamination control starts with the PhoXi 3D Scanner scanning each crate. The 3D scan is then used by PEKAT VISION machine learning algorithm to look for learned objects &ndash; candies. If the crate is contaminated, it is discarded.The filled crates are manipulated by a robot equipped with a special effector, which can grab 4 crates simultaneously.Discussion:The partner decided on a machine vision solution from Photoneo for several reasons:<ul><li>It is easy to install, set up, and integrate with the PLC system</li><li>The installation and configuration time is minimal</li><li>User-friendly interface</li><li>It works with the PEKAT VISION&nbsp;technology</li><li>The PhoXi 3D Scanner is reliable and precise</li><li>Great support during integration&nbsp;</li></ul>Would you like to discuss your project requirements with the Photoneo team? <a href="https://www.photoneo.com/contact-us/" rel="noopener noreferrer" target="_blank">Contact them here</a>.

In this application by Rossum Integration s.r.o., empty crates are scanned with the Photoneo PhoXi 3D Scanner to make sure they are not contaminated by candy products previously filled in the crates. After the contamination control, the crates are filled with a material and manipulated by a robot equipped with a special effector, which can grab 4 crates simultaneously.

Automated control and filling of crates

MetraSCAN 3D is a high-performance CMM, yet it is easy to operate. New employees who have been with the company for only a few months quickly learn to operate it, and they are now measuring products as part of their daily work.

High-speed, high-precision 3D scanner greatly streamlines the measurement work of wood model makers, which is a labor-intensive and time-consuming process.

Sakai Increases the Efficiency of its Dimensional Inspections with a New Approach

For over 60 years,&nbsp;<a href="https://hidrostal.com/" target="_blank">Hidrostal</a> has been manufacturing high-quality, low-maintenance pumps, ranging from small, portable pumps for construction sites and flooded basements to ten-ton wastewater and thick matter pumps.Hidrostal has been using optical measuring systems for more than 15 years. In the past, a 3D scanner with structured light and strip projection, made by a well-known manufacturer, was used for both the quality control and reverse engineering of cast parts ranging from 10&nbsp;cm to 2,500&nbsp;cm. This conventional measuring system was no longer generating the level of results required. Hidrostal decided to look for a new device that would overcome the weaknesses of the company&rsquo;s current system. Hidrostal wanted a system that would be easier to use, better capture difficult-to-access areas, and require less time for the scanning process. Moreover, the team wanted to capture the processed surfaces of cast parts without having to use any scanning spray.An on-site demo of the&nbsp;<a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d" target="_blank">Go!SCAN SPARK</a> at Hidrostal&rsquo;s facilities made a particularly good impression as it enabled the team to save several hours compared with the technology the company had been operating, and, on top of that, it was also easier to use.<h2>Application areas</h2>Now, Hidrostal uses the Go!SCAN 3D for, among other things, the reverse engineering of oil chamber casings with the aid of Geomagic Design X.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1677073161615-1677073161615.png" style="width: 766px;" class="fr-fic fr-dib">Another application area is the actual comparison of printed sand cores using <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" id="isPasted" target="_blank">VXmodel</a>.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1677073185307-1677073185307.png" style="width: 766px;" class="fr-fic fr-dib">J&ouml;rg Wessler, a technical modeler at Hidrostal, explained: &ldquo;The Go!SCAN 3D has done much more than replace the old scanner. It offers other benefits by being easy to use and reaching deep scanning surfaces. What we also really like is that the scanner can be operated intuitively. This means that the onboarding was very simple: we could implement what we had learned immediately and productively. The 3D scanner fulfilled all our expectations.&rdquo;&nbsp;

An on-site demo of the Go!SCAN SPARK at Hidrostal’s facilities made a particularly good impression as it enabled the team to save several hours compared with the technology the company had been operating, and, on top of that, it was also easier to use.

3D scanning for reverse engineering and the QC of cast parts in the pump industry

Partners:<a href="https://imr.ie/" target="_blank">Irish Manufacturing Research (IMR)</a>, <a href="https://www.airbus.com/en" target="_blank">Airbus</a>, <a href="https://teg.com/" target="_blank">TEG</a>, <a href="https://robotnik.eu/" target="_blank">Robotnik</a>, <a href="https://www.qub.ac.uk/sites/nitc/" target="_blank">Northern Ireland Technology Centre, Queens University Belfast</a>, <a href="https://hexagon.com/" target="_blank">Hexagon</a>, <a href="https://www.kuka.com/" target="_blank">Kuka Robots</a>, <a href="https://www.mvtec.com/" target="_blank">MVTec</a>, <a href="https://multipix.com/" target="_blank">Multipix Imaging</a>, <a href="https://www.photoneo.com/" target="_blank">Photoneo</a>, <a href="https://www.eurekanetwork.org/" target="_blank">EUREKA</a>, <a href="https://www.enterprise-ireland.com/en/" target="_blank">Enterprise Ireland</a>, <a href="https://www.cdti.es/" target="_blank">the Centre for the Development of Industrial Technology</a>Challenge:MAAS (Measurement Aided Assembly of Large-scale Structures) is a 2-year project funded by <a href="https://www.smarteureka.com/" target="_blank">SMART EUREKA</a> and supported by <a href="https://www.enterprise-ireland.com/en/" target="_blank">Enterprise Ireland</a> (EI) and <a href="https://www.cdti.es/" target="_blank">the Centre for the Development of Industrial Technology</a> (CDTI).The aim of MAAS was to improve the way airplane wings were made by developing an efficient automated solution &ndash; an end-to-end assembly process &ndash; for the manufacturing of aircraft sub-assemblies, with a focus on <a href="https://www.airbus.com/en" target="_blank">Airbus</a>&rsquo;s wing manufacture.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjc2MjgzNzUwOTYwLTE2NzYyODM3NTA5NjAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" width="579" height="327" srcset="https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMR-3-400x226.jpg 400w, https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMR-3-1024x579.jpg 1024w, https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMR-3-768x434.jpg 768w, https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMR-3-424x240.jpg 424w, https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMR-3.jpg 1300w" sizes="(max-width: 579px) 100vw, 579px" class="fr-fic fr-dii">&nbsp;The project included the development of an efficient robotic 3D scanning solution that could scan and inspect full aircraft wings at the high speed with the high accuracy needed to generate digital 3D scans of the aircraft parts for best ﬁt assembly operations. TEG and IMR worked closely to identify, develop, and deliver a novel wing and panel 3D scanning and measurement solution for parts assembly and the manufacture of wings.&nbsp;&ldquo;The grand challenge was to assemble airplane wings,&rdquo; explains Ken Horan, Director of Robotics and Automation at IMR. &ldquo;Within that, the problem in aircraft assembly was the expense of manufacturing due to variability in panels and wing fames resulting in screw hole misalignment or panel to panel step height and gaps out of specification. An automated system that could scan the frame, panels, locate, measure, and identify the best fit panel for a particular section of wing, to provide ease of assembly and screwing, was required.&rdquo;The final goal was to integrate the solution into a prototype robot-assisted assembly line to demonstrate a production cell integrating all the above described processes.Solution:<a href="https://www.photoneo.com/phoxi-3d-scanner" target="_blank">PhoXi 3D Scanner</a>The team developed an end-to-an automated solution for the assembly process of manufacturing airplane wings.This included a robot scanning solution based on the PhoXi 3D Scanner from Photoneo, which was used for 3D scanning and inspection of aircraft wing parts using a mobile collaborative robot platform to enable robot-assisted assembly and quality assurance of the final sub-assembly by 3D scanning techniques.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjc2MjgzNzUxMjI0LTE2NzYyODM3NTEyMjQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" width="679" height="384" srcset="https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMRS-2-400x226.jpg 400w, https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMRS-2-1024x579.jpg 1024w, https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMRS-2-768x434.jpg 768w, https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMRS-2-424x240.jpg 424w, https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMRS-2.jpg 1300w" sizes="(max-width: 679px) 100vw, 679px" class="fr-fic fr-dii">Methodology:<ol><li>The system consisted of a mobile collaborative robot that scanned the wing panel and performed assembly operations</li><li>3D data analysis allowed fast matching of panels with appropriate assembly locations</li><li>The system was able to carry out post assembly scanning for the measurement of gaps and step heights between panels</li></ol>Discussion:The MAAS project finished in late 2021, bringing about real business-to-business opportunities and valuable strategic partnerships between Irish SMEs, their European peers, and Airbus.The implementation of the project outputs is expected to bring significant efficiencies to aircraft wing assembly, including reduced costs in the aircraft assembly operations and improvement of manufacturing processes.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjc2MjgzNzUxMTA2LTE2NzYyODM3NTExMDYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" width="678" height="383" srcset="https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMR-1-400x226.jpg 400w, https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMR-1-1024x579.jpg 1024w, https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMR-1-768x434.jpg 768w, https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMR-1-424x240.jpg 424w, https://www.photoneo.com/wp-content/uploads/2023/02/CS-IMR-1.jpg 1300w" sizes="(max-width: 678px) 100vw, 678px" class="fr-fic fr-dii">The MAAS project was funded by <a href="https://www.smarteureka.com/" target="_blank">SMART EUREKA</a> and supported by <a href="https://www.enterprise-ireland.com/en/" target="_blank">Enterprise Ireland</a> (EI) and <a href="https://www.cdti.es/" target="_blank">the Centre for the Development of Industrial Technology</a> (CDTI).The multinational consortium comprised <a href="https://www.airbus.com/en" target="_blank">Airbus</a>, <a href="https://teg.com/" target="_blank">TEG</a>, <a href="https://imr.ie/pages/maas/" target="_blank">IMR</a> and Spanish robotics experts <a href="https://robotnik.eu/" target="_blank">Robotnik</a>. <a href="https://www.qub.ac.uk/sites/nitc/" target="_blank">Northern Ireland Technology Centre, Queens University Belfast</a> and other European SMEs such as <a href="https://hexagon.com/" target="_blank">Hexagon</a>, <a href="https://www.kuka.com/" target="_blank">Kuka Robots</a>, <a href="https://www.mvtec.com/" target="_blank">MVTec</a>, <a href="https://multipix.com/" target="_blank">Multipix Imaging</a>, and <a href="https://www.photoneo.com/" target="_blank">Photoneo</a> were also involved with supply of hardware and expertise.<a href="https://imr.ie/" target="_blank">Irish Manufacturing Research (IMR)</a> is one of Ireland&rsquo;s leading technology centers with extensive robotics expertise, a founding member of <a href="https://www.smarteureka.com/" target="_blank">SMART EUREKA</a>, holding the vice chair seat on the board.<a href="https://www.eurekanetwork.org/" target="_blank">EUREKA</a> is a European-founded public network for international cooperation in research, development, and innovation, operating in 48 countries. SMART is a EUREKA cluster programme, and offers a framework to bring together SMEs, large companies, and research performing organizations to collaborate on international research projects in advanced manufacturing.<a href="https://teg.com/" target="_blank">TEG</a> is a specialist Irish engineering firm and long-term strategic partner to IMR with metrology expertise in highly regulated environments such as biopharmaceutical facilities. They helped with the project with their EASA approved aviation design and production skills and the use of 3D scanning technologies. TEG benefited from MAAS too as the project provided an ideal opportunity to expand their business opportunities, highlight their capabilities in innovative technologies and their professionalism in project management by engaging in research with a global aerospace leader.<a href="https://www.airbus.com/en" target="_blank">Airbus</a> &ndash; a global pioneer in the aerospace industry, which provided first-class expertise in aircraft manufacturing and assembly.For more reference, check out the <a href="https://imr.ie/pages/maas/" target="_blank">IMR website</a> or <a href="https://horizoneurope.ie/horizon-europe/eureka-project-results-in-partnerships-for-irish-smes-and-airbus" target="_blank">Horizon Europe</a>.Would you like to consult your projects with Photoneo? <a href="https://www.photoneo.com/contact-us/" rel="noopener noreferrer" target="_blank">Contact them here</a>.

Assembly of airplane wing parts using the PhoXi 3D Scanner

The MAAS project team developed a unique, end-to-end solution for the assembly of airplane wing parts, which uses Photoneo 3D vision technology to handle challenges such as screw hole misalignment, panel to panel step height, and gaps out of specification.

End-to-end solution for 3D scanning and assembly of aircraft wings

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?

3D Scanning

Technical Guides

Measuring Surface Roughness: A Comprehensive Guide

Point clouds explained: scanning, processing, 3D models