<a href="https://www.iss-priorei.de/" target="_blank">I.S.S.</a><a href="https://www.iss-priorei.de/" target="_blank">&nbsp;Tooltec GmbH &amp; Co. KG</a> has been a competent partner to the steel and drop forging industry for wear protection and repair welding work for almost 15 years. This work is carried out on a variety of components such as dies, cutting tools, stretching rollers, forging saddles, rollers and drawing rings. The company also offers comprehensive advice on wear analyses and material selection, which helps extend the service life of valuable tools. Well-known customers from large-scale industry put their trust in the expertise, experience and quality of the work performed by I.S.S. Tooltec.In order to increase work efficiency and minimize costs and complaints, I.S.S. Tooltec GmbH &amp; Co. KG decided to implement 3D measurement technology, to carry out engraving comparisons on a wide variety of forming tools in the forging industry.Before 3D metrology equipment was introduced in the company, it was always difficult to estimate whether the amount of weld metal applied was sufficient to ensure that subsequent tool processing (engraving or milling) would be error-free. In addition, performing these measurements was also intended to help avoid using too much or too little welding material. Too much material means a high cost factor, too little means complaints from the end customer. The <a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d" target="_blank">3D scanner Go!SCAN SPARK</a> was exactly what they needed: it offers the required accuracy, flexibility, measuring speed, easy-to-use hardware and software, and is user-friendly – and Creaform provided the necessary training and support. Furthermore, it was good value for money. According to I.S.S. Tooltec, implementing the system into their daily business activities was very easy and training took place within a few days, so that they were able to handle the technology confidently in a very short time.<h2>Engraving comparison on a forming tool</h2>Tools are scanned before and after the welding process and compared with CAD data. This ensures that all the required welding quantities can be precisely adhered to.In this example, the 3D scan enables Tooltec to compare the tool they welded with the customer’s design file (CAD). This makes it possible to determine whether or not enough weld metal has been used.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714056831929-double_image.webp" style="width: 790px;" class="fr-fic fr-dib">3D scan in the VXinspect software and engraving comparison after welding on a forming tool with color comparison.The&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/vxinspect-dimensional-inspection-software-module" target="_blank">inspection software VXinspect</a>&nbsp;they used – a module of Creaform’s VXelements software suite – allows for dimensional inspections to be carried out and inspection reports to be created based on precise technical requirements. It is intuitive and guides the operator step by step through the inspection process: Scan &gt; Import scan file for CAD comparison &gt; Alignment &gt; Analysis &gt; Inspection report.I.S.S. Tooltec was impressed with the 3D scanner Go!SCAN SPARK and VXinspect: “The 3D measurement solution from Creaform has helped us to work significantly more efficiently and cost-effectively. We have already expanded the use of the scanner in our operations. In addition to the above-mentioned area of application, we now also use 3D scanners to perform scanning services.”

Management and customers demand realistic implementation of individual welding processes at low costs. These costs are often caused by inefficient work processes, such as reworking due to excess or insufficient use of materials, or customer complaints.

Use of 3D scanner increases efficiency and reduces labor and material costs

<a href="https://www.creaform3d.com/en/applications/quality-control-and-assurance-with-3d-measurement-technologies" target="_blank">Integrating 3D scanning technology into quality control processes</a> can be challenging. It requires balancing the need for cost-effective, scalable solutions with long-term effectiveness.We have compiled a list of our best tips to help you choose a 3D measurement technology that not only meets your current needs but also allows for future growth. This can save you valuable time and resources, and assist you in streamlining your quality control processes to better align with your business goals.<h2 id="isPasted">Step 1: Assess Your Current Needs</h2>To choose the right 3D scanning technology, you need to start by analyzing your current quality control processes and identifying the main challenges you want 3D scanning solutions to help you overcome.After that, you need to determine your specific needs. This includes considering the size and complexity of the objects you want to scan, the level of detail required, how you plan to use the data, the human resources available, and the skills of your quality control team.For instance, industries like aerospace and automotive require extremely high precision for quality control and validation. Meanwhile, other applications like cultural heritage preservation may prioritize the ability to capture colors and textures over geometric precision.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713430528437-HandySCAN3D_Helicopter_parts_2.webp" style="width: 100%px;" class="fr-fic fr-dib">If you’re struggling with a labor shortage or bottlenecks with your current metrology team, you will want to ensure that the 3D scanner you choose is user-friendly and intuitive for operators who are not metrology experts.<h2>Step 2: Consider Handheld 3D Scanners</h2>Moving from traditional quality control methods to fully automated systems can be expensive and complicated for most organizations. Installing a complete automated quality control system can cost more than half a million dollars, a significant investment for any business.An effective intermediary solution is to start with portable 3D scanning technology.&nbsp;<a href="https://www.creaform3d.com/en/portable-3d-scanners" target="_blank">Handheld 3D scanners</a> offer numerous advantages, such as:<ul><li>Flexibility: They can be used in various environments and are not limited to objects of a specific size or shape.</li><li>Cost-effectiveness: Handheld 3D scanners are significantly less expensive than their automated counterparts, making them a more accessible entry point for incorporating 3D scanning into your quality control processes.</li><li>Ease of use: Many models are designed with user-friendliness in mind, requiring minimal training and onboarding for quick integration within existing quality control workflows.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713430539552-HandySCAN-MAX_Scanner_Van-bumber_Remote-desktop-compatibility-2.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Step 3: Look for 3D Scanners with Integrated 3D Scanning Software</h2>The value of a 3D scanning solution extends beyond the acquisition of hardware. To optimize your investment, ask 3D scanner suppliers whether their solutions come with&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms" target="_blank">integrated 3D scanning software</a>. This will help minimize the risk of dealing with multiple hardware/software manufacturers and potential compatibility issues.Also, make sure you have a clear understanding of the integration capabilities of 3D scanning software. If you are currently using&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" target="_blank">CAD software</a> and are &nbsp;, it is crucial to rely on a manufacturer that can provide solutions that can be individually upgraded and adapted based on your specific context.This modular approach ensures that you won’t have to purchase a completely new system to benefit from the latest advancements in metrology when your quality control processes are ready.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713430564126-Automotive_Differential-Housing_CAD_on_laptop_220916519-2048x1365.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Step 4: Focus on Ease of Use and Manufacturer Support</h2>As mentioned before, it is crucial not to underestimate the importance of an easy-to-use 3D scanner. Many quality control teams struggle to find and retain skilled metrology professionals. Additionally, conventional CMMs often have capacity limitations that slow down the process. Adding 3D scanners should not worsen this problem.Thankfully, many of the latest 3D scanners are designed to be user-friendly. They are intuitive enough for individuals of all skill levels to pick up quickly, so there is no need to compromise current timelines and quality control KPIs.It’s important to not only consider the price when selecting a 3D scanner for quality control processes. Choosing the&nbsp;<a href="https://www.creaform3d.com/blog/why-using-low-cost-3d-scanners-in-professional-applications-can-be-a-costly-mistake/" target="_blank">cheapest option may lead to inaccuracies and undetected faults, which can negatively impact the quality of your products</a>. Additionally, opting for a 3D scanner that is not manufactured or designed in North America may result in less durable and reliable products.Furthermore, the quality of the 3D scanner and the level of support offered by the manufacturer, including training and after-sales support, are equally essential. To ensure maximum efficiency and productivity, it’s advisable to receive <a href="https://www.creaform3d.com/en/customer-support" target="_blank">good manufacturer training and support</a>. This should ideally be available worldwide to minimize downtimes and ensure that you are getting the most out of your 3D scanners.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713430570437-metrascan3d-scanning-inside-plane-VXelements-software2.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Step 5: Plan for the Future</h2>While choosing technology that meets your current needs is important, it’s equally essential to consider where your industry is headed and how your needs might change. For instance, if you start with a need for occasional quality checks, you may eventually require continuous quality control as your operations scale. Therefore, selecting a scalable solution from the start is essential.When looking for scanners, opt for those designed with the future in mind. This includes&nbsp;<a href="https://www.creaform3d.com/en/corporate/news-room/press-releases" target="_blank">manufacturers that regularly issue software updates and hardware add-ons as well as work with customers in a wide range of industries</a>, allowing for enhanced functionality as new technologies emerge.Market-leading 3D scanner manufacturers typically have a proven track record of innovating, updating, and supporting their metrology solutions over years, if not decades. A company’s commitment to improving its product lifecycle and ensuring long-term research and development indicates how well it will support your evolving needs.<h2>Conclusion: The Lasting Value of Choosing the Right 3D Scanner</h2>The process of improving quality control through 3D scanning should not be just a short-term procurement decision. It’s a strategic choice that will help your business thrive in the future.Choosing the right 3D scanning technology is crucial to balance current needs and future flexibility. It’s a commitment to enhancing quality standards while staying competitive in the market. By adopting portable 3D scanners, supported by solid software and manufacturer support, you can lay a foundation to withstand technological advancements and market fluctuations.Visualize your quality control processes not just as they are, but as they could be. By selecting solutions that promise scalability, you can ensure that your initial investment will turn into a long-term asset that continues to deliver results for years to come.Therefore, choose the option that puts your business at the forefront of quality control, and assures you that when the future of 3D scanning innovations arrives, you will be ready to implement them with confidence.

Creaform have compiled a list of their best tips to help you choose a 3D measurement technology that not only meets your current needs but also allows for future growth. 

Smart Steps to Integrating 3D Scanning in Your Quality Control

Do you ever question the accuracy and reliability of your quality control (QC) process? Do you ever doubt the quality of your measurement setup, especially if you are a non-expert in 3D scanning? Have you ever measured large parts that required moving the equipment to expand the measuring volume and questioned if there was a cumulative error that could distort the results?Knowing that decisions can be misguided without a reliable QC process and lead to costly errors, it is crucial to ensure that your measurements are as accurate as possible. If you are unsure about your current QC process, this blog can offer innovative solutions.<h2 id="isPasted">Unreliable QC Process</h2>Doubt can impair decision-making that will directly impact product quality. <a href="https://www.creaform3d.com/blog/how-to-better-detect-manufacturing-defects/" target="_blank">Accepting parts that do not meet requirements</a> while rejecting parts that comply with standards are costly errors that ultimately undermine customer satisfaction and company revenue. Therefore, companies must &nbsp; and understand where this doubt in measurement accuracy and reliability stems from.<h2>Origin of Doubt, Sources of Bad Decisions</h2>Various factors can influence measurement accuracy and reliability in QC processes, leading to bad decision-making. Simply put, errors may arise in QC processes due to three main factors: the measuring equipment, the user conducting the measurements, and the environment or measuring methods around and between the equipment and the user.<h3>Measuring Equipment</h3>Equipment certified according to relevant standards, such as ISO, has been thoroughly tested and qualified to meet specific performance criteria. This ensures its capability to produce accurate, repeatable, and reliable measurements. On the other hand, equipment that has not undergone rigorous testing and meticulous qualification may perform poorly or function inadequately, regardless of who uses it. Opting for <a href="https://www.creaform3d.com/blog/3d-scanning-for-inspection-a-smart-choice/" target="_blank">high-quality equipment</a> engineered by renowned manufacturers typically results in greater accuracy, more reliable measurements, and software features that minimize user error, compared to lower-quality alternatives.<h3>User</h3>Human error is regularly cited as a primary source of error in various processes, including measurement and quality control, despite advances in automation. This is often due to a lack of technical expertise, which has been a significant challenge in recent years. As a result, users without the requisite technical background may not use the equipment correctly, leading to measurement errors and affecting the data quality. This misuse can be caused by a lack of guidance on how to operate the equipment or by not performing the correct setup, which is necessary to ensure accurate measurements.<h3>Environment and Measuring Methods</h3>Equipment performance can also vary depending on the environment and measuring methods used. For instance, quality control of large parts cannot always be carried out in a metrology lab. Inspection must often be conducted directly in the production environment, where vibrations and thermal variations can impact validation jigs, resulting in inaccurate and non-repeatable measurements. Additionally, when dealing with large parts, leapfrogs are often required and can introduce an additional, unspecified error that further contributes to measurement inaccuracy.Therefore, to reject the bad parts and keep only the good ones, QC specialists and metrologists must take all necessary measures to minimize and, ideally, eliminate any uncertainty from all sources. This is an essential step for maximizing overall confidence in the QC process and creating an ideal environment for making confident and informed decisions.<h2>Eliminate Errors in your QC Process</h2>Creaform is introducing three new improvements to the <a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan/technical-specifications" target="_blank">MetraSCAN BLACK+</a><a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan/technical-specifications" target="_blank">TM</a> to help eliminate errors in your QC process. The new acceptance tests based on ISO 10360 provides better confidence in the measurement equipment, ensuring accurate measurement results. Adding new specifications and easy-to-use 360 magnetic targets further enhances measurement accuracy, especially for large parts that require leapfrogging. Finally, the latest guidance tools make it easier for non-experts to use the measurement tool efficiently and correctly.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712821737338-Large_part_being_scanned_MetraSCAN-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib">Engineer scanning a massive part with the Creaform MetraSCAN BLACK+<h3 id="isPasted">1. New Acceptance Tests Based on ISO 10360</h3>What is more important than trusting the accuracy specified on a manufacturer’s specification sheet? The best way to generate this trust is to rely on international standards, such as ISO, which has an impeccable reputation in the industry and a proven track record in QC processes. This is why the performance of the MetraSCAN BLACK+ is now also validated based on ISO 10360, in addition to being certified according to the German standard VDI/VDE 2634 part 3.Moreover, Creaform’s acceptance test and performance assessment now include two new specifications: the form error on a sphere and the form error on a flat surface.Concretely, this indicates that our 3D scanners must undergo a more rigorous process and succeed in more performance tests before being shipped to customers, resulting in better-quality products without exceptions. By being fully transparent about our qualification and certification acceptance tests, customers can be confident in the product performance and Creaform’s stated accuracy.<h3>2. QC on Large Parts Simplified with Automatic Volume Extension and 360 Magnetic Targets</h3><a href="https://www.creaform3d.com/blog/do-you-have-trouble-measuring-and-analyzing-large-parts/" target="_blank">Inspecting large parts</a> often requires extending the reach of the measuring device. A measuring arm may have physical limitations that necessitate leapfrogging to expand its volume. Even with equipment having deep measuring volume, line-of-sight issues can occur when measuring hidden areas (like the back of a car), leaving no option but to move the device to have a more direct field of view.Proceeding with leapfrogs has two significant drawbacks in QC processes. The more leapfrogs there are, the more the volumetric accuracy deteriorates, and the longer it takes to complete the QC process, especially with measuring arms that must be repositioned at each step. The problem is that most measuring equipment manufacturers do not specify the impact of leapfrogging in their specifications, leaving users in doubt about the measurement accuracy.Creaform introduces more updates to its MetraSCAN BLACK+. The Automatic Volume Extension (AVE) feature has been enhanced and now includes a specification (0.025mm + 0.015mm/m), indicating that a 5-meter part can be measured with an accuracy of 0.100mm. Additionally, new 360 magnetic targets have been added to improve tracking. These enhancements solve the leapfrog issue, allowing users to move the C-Track and perform real-time photogrammetry with greater accuracy and speed.Automatic Volume Extension (AVE) The AVE feature allows for automatic acquisition volume extension only by moving the C-Track without requiring extra measurements. Creaform’s advanced integrated photogrammetry and scaling algorithms ensure a more precise, repeatable, and human-error-free measurement of large parts.360 Magnetic Targets With their crafty design, the new 360 magnetic targets are automatically detected from any angle by the C-track, making tracking easier and setup quicker. Users, whether they are experts or beginners, can now effectively scan large parts and get accurate and reliable measurements.See how the QC process is simplified for large parts with the AVE feature and new 360 magnetic targets.<iframe width="640" height="360" src="https://www.youtube.com/embed/ZIS3pLxrykU?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><h3 id="isPasted">New Setup Assistance Tools</h3>The MetraSCAN BLACK+ now comes equipped with setup assistance tools designed to help new or inexperienced users get up to speed quickly and feel confident using the device, even without extensive prior knowledge.Using live visual feedback, the software helps the user position the targets in the right number and places.The guidance volume display simplifies the setup process and allows users to make swift adjustments. The assistance tools also provide users with advanced setup diagnostics, which help them troubleshoot and validate their setup before starting a new acquisition. Using a target deviation table and vectors, they can determine if there were any deviations since the targets were positioned. This lets them conclude whether the jig has been impacted or thermally deformed.Check out how the Setup Assistance Tools help users troubleshoot their setups.<iframe width="640" height="360" src="https://www.youtube.com/embed/Ejown4IhHOI?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>In short, the setup assistance tools—with their live feedback on positioning targets and advanced troubleshooting assistance—provide guidance for setup preparation, making it easier for non-experts to use their measuring equipment and to be confident in their QC process.<h2>Make the Right Decisions Based on Accurate, Repeatable, and Reliable Data</h2>With these new improvements to the MetraSCAN BLACK+, Creaform is taking a step further to reduce errors that can occur in the QC process. Now, the performance of the measuring equipment is validated based on ISO 10360 for better accuracy. The user, whether expert or beginner, is better guided during setup execution. Measuring methods requiring leapfrogging are now better documented and easier to perform. Users can also troubleshoot their setups to ensure environmental conditions have not created deviations.Therefore, if all sources of error are eliminated from the equation and you no longer doubt the equipment, the user, or the environment and measuring methods, then you make the right decision with confidence, knowing that the default can only come from the part that must be reworked or rejected. This is how you can regain confidence in your QC process.Learn more about the New <a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan/technical-specifications" target="_blank">MetraSCAN BLACK+</a>.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712821796433-metrascan3d-car-frame-scanning-1-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib">Engineer scanning a car body with the Creaform MetraSCAN BLACK+

Engineer scanning a massive part with the Creaform MetraSCAN BLACK+

Do you ever question the accuracy and reliability of your quality control (QC) process? Do you ever doubt the quality of your measurement setup, especially if you are a non-expert in 3D scanning?

Do you have confidence in your 3D measurements? Are you certain they are accurate, repeatable, and reliable?

The automotive industry is undergoing a huge transformation. As the world moves towards more sustainable energy sources, electric vehicles (EVs) are becoming a driving force to transition from gas-powered cars. Just recently, <a href="https://www.gearpatrol.com/cars/g34452328/future-electric-cars/" target="_blank">Gear Patrol</a> and <a href="https://www.caranddriver.com/news/g29994375/future-electric-cars-trucks/" target="_blank">Car and Driver</a> have showcased future EVs from a wide range of automotive manufacturers, including Acura, Audi, Mercedes, Chevrolet, Ford, BMW, Polestar, Kia and Hyundai, just to name a few. Even luxury car brands, like Alfa Romeo, Maserati and Bentley, are jumping on the EV bandwagon.What’s more, <a href="https://www.cnbc.com/2023/06/16/converting-gas-powered-cars-to-evs-is-a-booming-business.html" target="_blank">shops and the aftermarket sector are noticing a substantial increase in demand for converting combustion vehicles to electric</a>, propelled by demand from DIYers and classic car collectors.But developing EVs or converting traditional cars to electric is not a mere battery-swapping game. It’s a complex process involving precision, detail, and innovative engineering. At the heart of this new approach to vehicle design is 3D scanning technology.We sat down with one of Creaform’s clients, <a href="https://www.phiaro.jp/en/" target="_blank">Phiaro</a>, to learn more about how the company is utilizing 3D scanners to convert conventional vehicles into EVs for its clients.Based in Japan and with <a href="https://phiaroinc.com/" target="_blank">offices in Irvine, California</a>, Phiaro is an industrial engineering company that offers research, design, and product development services to the automotive sector. In the business for over 80 years, the company has carved an enviable niche in the market for constantly pushing the technology envelope further.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711016488267-photo_01-1536x864.webp" style="width: 100%px;" class="fr-fic fr-dib">Phiaro’s engineering managers see a promising future for Creaform’s 3D scanners in their EV design and inspection workflows<h2 id="isPasted">3D scanning: A pivotal technology for designing brand-new EVs</h2>When manufacturers embark on a new project to create an innovative EV model, metrology-grade 3D scanners allow engineers and industrial designers to accurately acquire 3D measurements of existing combustion-engine vehicles, which can then be used as the springboard for designing its EV counterpart.Traditional vehicle design methods, involving multiple physical prototypes and iterations, are both time-consuming and resource-intensive. Using 3D scanners can substantially reduce the costs associated with these EV development processes, making them more efficient and accelerating an automotive manufacturer’s time to market.The design teams at Phiaro use Creaform’s Go!SCAN SPARK to replace their conventional methods of taking photographs with a digital camera or using legacy equipment fixed to a jig to conduct tests on the vehicles they are designing. Both of these methods were cumbersome as not all the information was readily available to Phiaro’s development teams or did not offer the level of accuracy required for engineering and performance assessments. The Go!SCAN SPARK generates measurements without the use of positioning targets which saves a lot of time, and it captures precise texture info together with color.<iframe width="640" height="360" src="https://www.youtube.com/embed/56-pzC8vm_I?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><h3 id="isPasted">Combining the power of 3D scanning and mixed reality technologies</h3>Always ahead of the curve when it comes to adopting new technologies, Phiaro is also using the Go!SCAN SPARK, along with mixed reality (MR) technologies, to recreate accurate virtual models of vehicles. These models, when integrated with mixed reality tools, provide a virtual playground for engineers. They can “explore” the car, “see” the components in 3D space, and virtually confirm the design of EV engines, for example, when they are installed in the actual vehicle space.This virtual validation process drastically cuts down design and testing time. It also provides a tangible way for engineers across the globe to collaborate in real time. Imagine an engineer in Saitama working on a design and a colleague examining the outcomes in Tochigi, Japan, virtually walking around the same car model, providing instant feedback, and confirming changes.Phiaro’s engineering managers see a promising future for Creaform’s 3D scanners in their EV design workflows. As many in the automotive industry know, the sector is just getting started when it comes to innovations in EV design and performance.

Phiaro’s engineering managers see a promising future for Creaform’s 3D scanners in their EV design and inspection workflows

The automotive industry is undergoing a huge transformation. As the world moves towards more sustainable energy sources, electric vehicles (EVs) are becoming a driving force to transition from gas-powered cars.

3D scanning for gas-powered cars conversions of electrical vehicle design

<h2 id="isPasted">Insights into the Inspection Challenges Arising during Sheet Metal Manufacturing.</h2>Manufacturing sheet metal is far from a simple task. It requires rigorous inspection, primarily due to the high quality and stringent safety standards required in the automotive industry. No doubt, a combination of advanced technology and skilled labor must be involved to ensure that the sheet metal components are cut and shaped to precise dimensions. This includes checking for correct length, width, surface profile, and overall shape. Quality inspection is vital because automotive sheet metal must withstand stress and fatigue over the vehicle’s lifetime.Apart from ensuring safety, quality inspection also ensures that the visual standards of consumers are met. This is achieved by guaranteeing that parts are assembled with the best possible flush (height on either side of a gap) and the smallest gap (width of a strip between two car components, e.g. door and chassis).This blog post addresses the inspection challenges involved in sheet metal manufacturing. If you are looking to enhance the quality of your sheet metal parts, balance the thoroughness of inspections with cost and time efficiency, and gain some tips that could give you an edge over your competitors, this article might pique your interest.<h2>The Most Popular Manufacturing Techniques for Sheet Metal</h2>Stamping and laser cutting are among the most commonly used methods for manufacturing sheet metal components in the automotive industry. Both techniques require some level of dimensional inspection, ensuring that parts meet specified dimensions and tolerances. However, the extent and nature of the inspection vary depending on the process used.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817909876-Industrial-press-for-sheet-metal-stamping-and-CNC-laser-machine-cutting-sheet-metal-1536x507.webp" style="width: 100%px;" class="fr-fic fr-dib">CNC laser machine cutting sheet metal with light spark. Technology plasma industrial, Blue steel color.<h3 id="isPasted">Stamping</h3>Stamping involves using a stamping press to transform flat sheet metal (in either blank or coil form) into a net shape. This method is used to manufacture high-volume parts like frames, hoods, doors, and panels. Dimensional inspection is crucial in this process due to the high volume and precision required for these automotive parts. Inspections typically focus on checking the dimensions of features like holes, flanges, and bends, as well as overall part geometry.<h3>Laser Cutting</h3>Laser cutting, on the other hand, is used for cutting precise shapes in metal. It is typically used to produce intricate components or those that require a high degree of accuracy. Precision is key in laser cutting, so inspection typically focuses on the accuracy of cut dimensions, edge quality, and the position of features like holes or cutouts.In each of these techniques, various tools and instruments can be used for dimensional inspection, such as traditional calipers and micrometers, coordinate measuring machines (CMMs), or laser scanning and 3D metrology tools. The choice of measuring equipment depends on the complexity of the parts, the precision required, and the production volume.Laser 3D scanning is particularly advantageous for inspecting parts with complex shapes and detailed features or when high precision is required. Its ability to quickly capture a part’s entire geometry in high detail makes it a valuable tool, particularly for sheet metal manufacturing.<h2>What to Inspect on a Sheet Metal Part</h2>On sheet metal, certain features and dimensions are particularly critical to inspect due to their importance in the structural integrity and functionality of the part. Moreover, some bends or curved areas are often challenging to form and are prone to issues like spring back or deformation. Hence, manufacturers must control the quality of their parts, particularly the overall shape and edges.<h2>Keys Points for Controlling the Overall Shape</h2>Objective: Detecting any warping or distortion that might have occurred during manufacturing.While common, regular shape control involves a flatness tolerance, the inspection of complex 3D geometries involves a profile of a surface (or surface profile) tolerance.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817936809-GDT-in-VXinspect_Sheet-Metal-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib">Mockup image of a businesswoman using laptop with blank white desktop screen with coffee cup on wooden table in cafe<h3 id="isPasted">Flatness</h3>Symbolized by a parallelogram in GD&amp;T, a flatness tolerance specifies a tolerance zone defined by two parallel planes within which the surface or derived median plane must lie.<h3>Profile of a surface</h3>Represented by a half-circle in GD&amp;T, the tolerance zone established by the profile of a surface tolerance is 3D (a volume), extending along the length and width (or circumference) of the considered features.The profile of a surface tolerance is similar to the flatness tolerance. However, it uses the geometry of the part to create a tolerance envelope that conforms to the shape of the part, rather than a flat plane. Tolerances for sheet metal parts can be applied to the entire part or specific areas. Local tolerances are indicated on the 2D drawing and are necessary for tighter assemblies in specific locations.Moreover, tolerances (both flatness and profile of a surface) can be free in space, orientation, and position (no datum) or constrained to a specific alignment. This will affect the results, as a fully constrained profile of a surface tolerance will create an envelope that perfectly follows the geometry of the part, without any allowance for movement in space to fit all the points inside the envelope.<h2>Key Points to Inspecting Edges and Corners</h2>Objective: Detecting deformities and irregularities that might have appeared during the cutting and shaping processes.On common sheet metal parts, two types of edges are mostly present: sharp edges and hemmed edges.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817960526-HandySCAN3D_Sheet-Metal-Car-Part-Inspection-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 id="isPasted">Sharp Edges</h3>Sharp edges are mostly found on sheet metal parts that are laser-cut or stamped with a punch tool or die.<h3>Hemmed Edges</h3>Rather than sharp edges coming from stamping or laser cutting, hemmed edges present a rounded shape found in places prone to injuries, such as the contour of a car door.In the process of stamping and laser cutting sheet metal, certain edges of circles, oblongs, or part sides can become very sharp, which can be dangerous and cause injury or damage if left untreated. Therefore, it is necessary to deburr these edges to break their sharpness and straightness.To ensure that the edges, both hemmed and sharp, are safe and of high quality, manufacturers must accurately inspect their position, angle, and straightness. To achieve this, special algorithms have been developed and contribute to improving sheet metal manufacturing processes.Learn more about VXinspect’s Edge method, designed specifically for sheet metal edges<h2>More Areas to Control on Sheet Metal</h2>Holes, Oblongs, and Cut-Outs: Precision is key for holes, oblongs, and cut-outs in sheet metal parts, as they often need to align with other components. Inspecting these features ensures they are the correct size and properly positioned.Flanges and Tabs: Flanges and tabs are critical for the assembly process. Their dimensions and angles must be precise for proper fitment with other automotive parts.In short, when inspecting these key areas, you can ensure that sheet metal parts are manufactured to the correct dimensions and tolerance. You also confirm that they are the closest to the nominal design, and interference risks are mitigated. With no physical or functional interference, all parts fit together seamlessly and function as intended in the final assembly. As a result, quality, safety, and comfort are optimized.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817982143-Sheet-metal_Quality-Control_MetraSCAN-3D_Geely-1536x1151.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Which Sheet Metal Parts Are More Challenging to Inspect</h2>Certain parts pose more inspection challenges than others. Here are a few examples.<h3>Roof</h3>The roof of a car plays a vital role in ensuring passenger safety, which is why inspecting it is of utmost importance. However, due to its large size, measuring specific points directly on the assembly line can pose accessibility problems, requiring adapted tools. Therefore, when choosing the right inspection method, it’s not only the part itself that must be considered, but also the condition in which the part is inspected. This is particularly important in an automated quality control (AQC) context or for troubleshooting purposes.<h3>Doors and Fenders</h3>Parts that have structural rigidity once assembled, such as doors, do not need to be physically conformed before inspection. However, other parts, like front and rear fenders, that do not have structural rigidity, must be conformed. Conforming a part can be easy if the appropriate checking fixture is available. (Checking fixtures are typically designed for a specific part.) However, in today’s manufacturing world, production is shifting from Low Mix-High Volume to High Mix-Low Volume. This shift demands more checking fixtures, which in turn adds extra costs to the manufacturing and inspection processes.Holding fixtures are, however, more versatile than checking fixtures. They can be used on multiple parts, which reduces costs and saves storage space. Therefore, holding fixtures to which we add a fast measuring tool can significantly accelerate the conformation process.<h3>Car Body</h3>During the body in white (BIW) stage in which the car body’s frame is joined together, quality control is critical because it involves ensuring the quality of the vehicle’s metal framework before other components like the engine, chassis subassemblies, electronics, and interior trim are integrated into the structure. When inspecting large parts like the car body, pay close attention to the volumetric accuracy of the measuring tool used.Since the measurement deviation increases by a few microns per meter, the cumulative error of scanning a larger part is higher. Such deviations cannot be ignored, and scanning methods have been developed to reduce errors, such as using markers like passive or active targets and photogrammetry.<h2>Next Step: Understand the Technologies for Inspecting Sheet Metal</h2>Sheet metal parts must meet the high standards of quality and safety required by the automotive industry. Inspection is crucial to ensure that the manufactured parts are accurately dimensioned, thereby minimizing waste and reducing the need for rework, ultimately reducing production costs. This efficiency level is critical for any part manufacturer operating in the highly competitive automotive market.However, the manufacturing of sheet metal parts poses certain inspection challenges. To address these challenges, it is essential to select a suitable measuring technology among the different measurement solutions available by analyzing their respective advantages and disadvantages.

Manufacturing sheet metal is far from a simple task. It requires rigorous inspection, primarily due to the high quality and stringent safety standards required in the automotive industry.

Unveiling the Hidden Hurdles of Automotive Part Manufacturers

<h2 id="isPasted">The Use of Targets: A Significant Limitation</h2>Creaform has been advocating 3D scanning as an innovative solution for corrosion assessment for more than ten years. Throughout those years, however, we have seen a recurring demand for eliminating positioning targets during data acquisition. Indeed, more than a third of our users have identified the use of targets as a significant limitation of 3D scanning.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708692185631-Blog-NDT_graphics-01.webp" style="width: 100%px;" class="fr-fic fr-dib">Chart showing the main limitations of 3D scanning according to users (35%: positioning targets, 31%: software limitations, 23%: cable, and 12%: large components).<h2 id="isPasted">Solution: New HandySCAN 3D|MAX Series</h2>3D scanning technology, which still features unmatched precision due to its unique auto-positioning and tracking, is not yet ready to completely eliminate targets. However, Creaform has recently introduced a significant innovation to address this issue. The <a href="https://www.creaform3d.com/en/handyscan-3d-max-series-for-large-objects" target="_blank">HandySCAN 3D|MAX Series</a>, a 3D scanner designed specifically for large parts, was added to the product portfolio. This new scanner has a much wider field of view, allowing users to significantly reduce the number of targets used during the scanning process. In some cases, the targets can even be spaced as far as 30 cm apart.Furthermore, to enhance the scanning experience and preparation, we have developed a new positioning accessory called the 360 Magnetic Target. These new positioning targets can be positioned and removed more quickly than traditional markers. In addition, their geometry makes them more easily detectable by the sensor, regardless of the angle or position the user is holding the scanner.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708692209084-Prior_Scanning_Setup_Inside_Rail_Car.webp" style="width: 100%px;" class="fr-fic fr-dib">NDT technician scanning a cylindrical section inside a rail car, surrounded by a multitude of positioning targets.On the one hand, the NDT industry is mostly made of large parts and bulky structures, which are challenging to inspect due to the high number of positioning targets they may require. On the other hand, NDT service companies demand as few positioning targets as possible. For this reason, we engineered the new magnetic marker so that users can install and uninstall them very quickly—and in limited numbers.So, what does this improved ease of use represent in terms of productivity gains?<h2>Productivity Gain: 75% Less Inspection Time</h2>To get a better idea of the impact of this improvement, we made an experiment. We scanned a Ford Transit minivan of similar dimensions to a rail car (34 m2 vs 32 m2) with the new HandySCAN 3D|MAX Series. We documented the time required to set up and scan these two vehicles. The inspection carried out with the MAX Series took 75% less time to complete than the one performed with the HandySCAN 700.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708692229854-2024-02-07-15_09_05-Window.webp" style="width: 100%px;" class="fr-fic fr-dib">Positioned halfway between conventional and long-range scanners, the MAX Series has been designed and optimized for measuring large parts and is the only <a href="https://www.creaform3d.com/en/ndt-solutions/ndt-pipeline-inspection-oil-and-gas-industry" target="_blank" id="isPasted">solution offered in the NDT market</a> with sub-millimeter precision.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708692237137-handyscan-max-ndt-solutions-refinery-Pressure-Vessel-1-LR-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib">NDT technician holding a HandySCAN MAX and inspecting the paint and corrosion of a pressure vessel with a few 360 Magnetic Targets positioned on the structure.<h2 id="isPasted">Faster Preparation and Enhanced Scanning Experience</h2>With the new MAX Series, NDT service companies have the opportunity to become more productive and gain in productivity. Moreover, they can now measure a series of structure dimensions and complex geometries that were simply impossible to assess before with such a high level of precision. This is the case for rail storage tanks, tank cars for transporting oil and gas, distillation columns, and pressure vessels, to name just a few.In short, the HandySCAN 3D|MAX Series, combined with VXintegrity, provides NDT services companies with the most precise solution for assessing large corroded areas, and the fastest experience, from setup preparation to part inspection.<h2>Watch the New Technology in Action</h2><iframe width="640" height="360" src="https://www.youtube.com/embed/gw9O6G5lWZU?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true"></iframe>

NDT technician holding a HandySCAN MAX and inspecting the paint and corrosion of a pressure vessel with a few 360 Magnetic Targets positioned on the structure.

The benefits associated with 3D scanning are unanimously acknowledged in the NDT industry. They involve the acquisition of data independent of the user’s expertise or experience, increased precision and repeatability, and significant productivity gains compared to more traditional techniques.

New 3D Scanner Revolutionizing Extensive Surface Damage Assessment

Our non-destructive surface evaluation solution for the pipeline industry has received valuable feedback since its launch last year. The suggestions for improvement include increasing the scanning capacity of our scanners and making our analysis algorithms more versatile for the geometries that our software supports.Creaform has been attentively listening to the feedback and requests for improvement from its valued customers. We also have noticed a persistent trend in the requests. It has become clear that the limited alternatives available in the market for this type of assessment, particularly for large components and curved surfaces, have been the primary reason for these demands.<h2 id="isPasted">Pit Gauge Challenges for Large and Corroded Structures</h2>The pit gauge is the preferred method for evaluating corrosion on large components due to its affordability and widespread availability in most industries. However, this technique has significant limitations.Operators using the pit gauge may struggle to measure irregularly shaped pits or those with complex geometries accurately. The tool is typically designed for relatively simple, cylindrical pits and may not provide accurate readings for more intricate corrosion patterns. Additionally, the reliability of measurements is contingent on the skill and experience of the operator. Interpreting pit gauge readings requires a certain level of expertise, and variations in technique among different operators may lead to measurement inconsistency. Finally, while pit gauges are effective for localized measurements, they may not be suitable for assessing overall corrosion across large surfaces. Indeed, on a large structure, it can be challenging and time-consuming for operators to probe all surfaces and report all indications using the pit gauge.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708009286416-area-with-severe-corrosion-pitting-1536x1024.jpeg" style="width: 766px;" class="fr-fic fr-dib">Zoom on an area with severe corrosion and pitting that is usually very challenging to inspect and for which asset owners have difficulties trusting the results.<h2 id="isPasted">Long-Range 3D Scanner Challenges for Large and Corroded Structures</h2>Long-range 3D scanners are gaining popularity with the democratization of Industry 4.0 and the widespread use of digital twins. Their use has increased over the past decade in various industrial applications, including the digitization of factories and critical infrastructures. These scanners are sometimes used to assess mechanical damages, such as dents in storage tanks or other large assets.However, they are not typically used for corrosion assessment due to their limited resolution. This lack of precision makes detecting minor irregularities or mild corrosion challenging, as long-range scanners may not capture fine details with sufficient resolution.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708009308397-handyscan-black-ndt-solutions-refinery-Valve.webp" style="width: 766px;" class="fr-fic fr-dib">NDT technician holding a metrology-grade 3D scanner and inspecting the corrosion on a corroded valve.<h2 id="isPasted">Why Are Metrology-grade 3D Scanners a Good Alternative to Those Solutions?</h2>Ten years ago, Creaform revolutionized the pipeline industry by introducing 3D scanning technology. Nowadays, any specialized pipeline inspection service company must possess Creaform’s 3D scanner pipeline inspection solution to secure a service contract.Compared to traditional techniques, the benefits of 3D scanning for corrosion inspection are significant. Metrology-grade 3D scanners are not only faster and more precise, but they also eliminate acquisition and reporting errors. With 3D scanning technology, generating reports on-site is now possible, which helps to make the right maintenance decision as quickly as possible with the most accurate data.Moreover, this type of inspection creates a digital clone of the inspected asset, allowing the inspection to be revisited with the highest degree of precision and even track the progression of damages over time.<h2>3D Scanning vs Manuel Techniques on Curved Surfaces</h2><iframe width="640" height="360" src="https://www.youtube.com/embed/YwqbxKIiaaE?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><h2 id="isPasted">New 3D Scanner Designed for Large Parts</h2>Creaform, continually recognized as a leading provider of 3D damage assessment solutions in the pipeline industry, is proud to announce the launch of a new metrology-grade 3D scanner for large parts. The HandySCAN 3D|MAX Series, combined with VXintegrity software, will transform the process of conducting damage assessments on large parts.With the new 3D scanner, mechanical damage assessments of large-dimension assets, such as those with API 650, API 570, and API 510, now take only a fraction of the expected inspection time.The MAX Series can digitize entire structures with a precision of 75µm, ensuring that the maximum thickness loss is captured. Once the surface is digitized, specialized software analyzes mechanical damages, such as corrosion or dents, without the need for CAD. The dimensions of all damaged areas are then automatically exported and documented.Furthermore, if a more precise corrosion rate is required for the next inspection, it is possible to compare two damaged areas very precisely and observe any changes compared to the previous inspection.<a href="https://www.creaform3d.com/blog/pun5th75ef_wp/wp-content/uploads/handyscan-max-ndt-solutions-refinery-Storage-tank-3-LR.jpg" target="_blank"> </a><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708009348106-handyscan-max-ndt-solutions-refinery-Storage-tank-3-LR-1536x1024.webp" style="width: 766px;" class="fr-fic fr-dib">NDT technician holding the HandySCAN MAX and inspecting corrosion under insulation at the bottom of a reservoir.<h2 id="isPasted">Right Equipment for Better Decisions Based on Accurate Data</h2>Evaluating corrosion on large surfaces can be time-consuming and error-prone, and reporting these big areas can get messy and inaccurate. Therefore, service companies may benefit from better equipment to counter these challenges. The new HandySCAN 3D|MAX Series makes it easier to communicate the indications while ensuring 100% inspection coverage and eliminating human error on the data. As a result, service companies can increase their productivity by making better decisions based on accurate data they can now fully trust.

NDT technician holding a metrology-grade 3D scanner and inspecting the corrosion on a corroded valve.

Creaform's non-destructive surface evaluation solution for the pipeline industry has received valuable feedback since its launch last year.

3D Scanning vs Manual Techniques: A Comparison of Their Effectiveness in Evaluating Large and Curved Surfaces

<a href="https://www.zeppelin-cat.de/en/" target="_blank">Zeppelin Baumaschinen GmbH</a> has been a German based sales and service partner of Caterpillar Inc., the world’s largest manufacturer of construction machinery, since 1954. Zeppelin Baumaschinen GmbH has in the interim developed into the largest business unit in the Zeppelin Group, and today it is Europe’s leading sales and service organization in the industry.The company has been using conventional metrology equipment for years, but for some tasks, this approach has now become obsolete. For example, there are no blueprints or geometry data available for many machines and components, especially older ones, and it is not possible to verify the dimensional accuracy of components with complex geometries using their traditional metrology equipment. The company therefore decided in June 2022 to expand its metrology equipment with a <a href="https://www.creaform3d.com/en/portable-3d-scanner-handyscan-3d" target="_blank">HandySCAN 3D|Black Elite</a> and the <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms" target="_blank">data capture software VXelements</a> with its <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" target="_blank">VXmodel scan-to-CAD module</a>.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA3Mzk5Mzk5NjA3LTE3MDczOTkzOTk2MDYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib"><h2 id="isPasted"><h2>3D scan of engine blocks including connection poin</h2></h2>In order to refurbish an existing engine test bench at the Cologne site, several engines had to be measured to create customized trolley mounts. With the help of these mounts, attaching the engines on the engine test bench becomes a quick and smooth operation.The current engine test bench is now 59 years old (it was built in 1962) and has reached the limits of its performance when some Caterpillar diesel engine series have to be tested. Assembling the engines on the test bench, as well as the set-up and dismantling for the test bench run, is very time-consuming and limits the engine throughput on the test bench.The new engine test bench will be used to test engines with an output of up to 1000 kW. In the future, the test objects will be assembled using so-called trolleys. The advantage is that the engines are pre-assembled on the trolleys, and the trolley with its test object is then quickly mounted in the test bench room.In order to accommodate, to the greatest extent possible, the widest range of engine types on the trolleys, it was decided to scan the majority of the engines with the <a href="https://www.creaform3d.com/en/portable-3d-scanner-handyscan-3d" target="_blank">HandySCAN 3D</a>. This has the advantage that the connection points of the media supply, such as fresh air and exhaust gas, as well as the dimensions of the flywheel for the individual engine types can also be captured.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA3Mzk5NTM0ODQ5LVplcHBlbGluX0ltYWdlLTQtMTUzNng4NjQud2VicCIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 766px;" class="fr-fic fr-dib">Engine block on the trolley mount. This makes it possible for the engine block, including connection points, to be digitized from all sides.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA3Mzk5NTY5NDQ4LVplcHBlbGluX0ltYWdlLTUtMTUzNng4ODQud2VicCIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 766px;" class="fr-fic fr-dib">Scan of the engine block in the VXelements data capturing software. The areas highlighted in green show the connection points for the test bench.<h3 id="isPasted">Advantages of the Creaform HandySCAN 3D and the VXelements software</h3>This project would have been difficult or even impossible to realize using traditional measurement equipment. Given the complex geometries of the engines, it would not have been possible to record the missing dimensions. It would also have been virtually impossible to reconstruct hidden elements.The scanning process itself has been optimized to such an extent that the engine measurement can now be carried out quickly:<ul><li>Preparation time approx. 1 hour</li><li>Measurement time approx. 0.5 hours instead of 2 hours</li><li>Post-processing/creation of the auxiliary construction varies from approx. 4-8 hours, depending on requirements</li></ul>In addition, thanks to the VXmodel software, preparation of the model for further development in CAD is considerably simplified.According to Zeppelin Baumaschinen, the&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" target="_blank">3D measurement software VXelements</a> offers clear advantages:<ul><li>Simple and reliable operations</li><li>Clear interface and functions</li><li>Direct interface to CAD software systems</li></ul><h3>Areas of application of the HandySCAN 3D|BLACK at Zeppelin</h3>Zeppelin Baumaschinen GmbH now uses 3D metrology equipment for a whole range of applications. These include:<ul><li>Damage analysis of assemblies and individual parts</li><li>Reverse engineering of existing machine components for individual modifications according to customer requirements (e.g. new development of individual components, customizing, and much more)</li><li>Creation of 3D models for training and education purposes</li><li>Creation of 3D models for adaptive component development / installations &amp; conversions on existing machines</li><li>Scan-to-print solutions for supply bottlenecks</li></ul>There are also plans to use the measurement solution in the future for other projects, such as adapting operating elements for people with disabilities, e.g., modifying a joystick.

Given the complex geometries of the engines, it would not have been possible to record the missing dimensions. It would also have been virtually impossible to reconstruct hidden elements.

3D Scanning Helps with the Design of Engine Block Mounts

<a href="https://www.intav-europe.com/en/index.php" target="_blank">INTAV SRL</a> is an Italian company with more than 30 years of experience in designing and manufacturing luminous and acoustic warning devices for emergency, rescue, and operative vehicles.To improve its technological measurement and design capacities, the company was looking for a metrology solution able to quickly capture part dimensions – especially when original drawing data could not be provided by the customer or supplier. Until then, measurements were made the old-fashioned way with manual devices such as caliper gauges and measuring tapes. This was extremely time consuming, and the results were not always precise. Consequently, the objective was to find a tool that would speed up the measurement process and would provide 3D data instantly for their projects, as well as for reverse engineering tasks.The&nbsp;<a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d" target="_blank">Go!SCAN SPARK</a> scanner convinced the company after a practical test, as it fulfilled all the requirements, and provided great value for money and precise data. The implementation was seamless, and, after some practice, all operators were able to use the scanning tool.<h2>Creation of side case shelters for motorcycles</h2>Recently the Go!SCAN SPARK was used for the creation for steel side case shelters for motorcycles.For this project, a motorcycle was partially scanned to get 3D references, in order to get data into the 3D CAD software SolidWorks.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1704882489255-GoSCAN-SPARK_Angle_Front_Left.webp" style="width: 300px;" class="fr-fic fr-dib">INTAV took advantage of the good quality of the scan to have very realistic chassis interfaces that could be used as a template to create the best possible fit with the part they needed to develop. The final product was assembled without problems, right out of the box.According to Hermann Molteni, Mechanical Designer at INTAV, the&nbsp;<a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d" target="_blank">3D scanner</a> greatly facilitated the process of integrating parts within both large and small narrow spaces. It enabled the generation of 3D drawings of parts, where no original drawings existed, to quickly have a replica produced in the design software SolidWorks. Overall, the scanner facilitated the work of the engineers and designers.

INTAV SRL is an Italian company with more than 30 years of experience in designing and manufacturing luminous and acoustic warning devices for emergency, rescue, and operative vehicles.

Revolutionizing Design: INTAV's Journey with 3D Scanning for Motorcycle Accessories

Based on the latest International Energy Agency (IEA) projections (featured in the newest edition of the <a href="https://www.iea.org/reports/global-ev-outlook-2023" target="_blank" id="isPasted">Global EV Outlook</a>), the share of electric vehicles (EVs) in the overall car market has risen from around 4% in 2020 to 14% in 2022 and is set to increase further to 18% in 2023. There is no doubt that demand for EVs is booming, and sales are set to surge to another record total this year.Government incentives, consumer behavior, and improvements in EV technology have all driven this significant growth. Governments around the world have introduced policies to encourage EV adoption. Consumer awareness has evolved, with increased demand for greener technologies and sustainable mobility modes. Battery technology also continues to improve, leading to longer driving ranges on a single charge. Finally, charging infrastructure is expanding rapidly to support the growing number of EVs on the road.New Parts but the Same Need for Quality ControlOEMs and part manufacturers who were used to producing traditional internal combustion engine (ICE) vehicles must now adapt to this sea change. The pivot from ICE to EV will disrupt the entire supply chain. As new parts must be developed and produced, the process of electrification will create a significant shift in market size for automotive components.Throughout all these changes, part quality must remain impeccable. Each part must comply with the highest quality standards and meet the tightest tolerances while also meeting the production throughput specifically required by the automotive industry.<h2>Some Challenges Awaiting EV Part Manufacturers</h2>Measuring Reflective MaterialsThe parts used in making EVs, such as the battery tray, are typically made from lightweight and durable materials like aluminum, steel, or composite materials, which are mostly reflective. Any measurement technology involving white or blue light is sensitive to surface finishes and may require surface preparation (in the form of powder application) to perform inspections properly. Such treatment means one more step in the inspection process, which means more time to manufacture and deliver the parts.Inspecting EV Parts While Increasing ThroughputTraditional inspection methods usually take time. Coordinate measuring machines (CMMs) are located in dedicated metrology labs, necessitating a lot of programming, setup, and back-and-forth with the production line. CMMs are not the fastest inspection tools and require metrology experts to operate them. In addition, they are often in high demand, busy with all types of inspections. All these extra steps congest and slow the inspection process, impairing the production throughput.Controlling Large and Complex PartsThe battery tray is the EV’s main structural part. Therefore, the trays are&nbsp;<a href="https://www.creaform3d.com/en/handyscan-3d-max-series-for-large-objects" target="_blank">large in size</a>, and a single person cannot move them easily. Moreover, they are produced in harsh environments with ubiquitous oscillations, vibrations, and thermal variations—not ideal for performing highly accurate measurements. On top of that, they also feature extrusions that can be laborious to measure with traditional tools.Solution: Accuracy on the Shop FloorIdeally, auto part manufacturers need to be able to inspect their large and complex parts directly on the shop floor without compromising on accuracy or requiring surface preparation. Their metrology instrument must measure more quickly and require less training, handling, and programming time than CMMs, which will help accelerate inspection time and increase production throughput.<h2>Why Dura Automotive Systems Chose Creaform</h2>DURA Automotive Systems is a global automotive supplier specializing in the design, engineering, and manufacturing of solutions that drive the evolution of mobility. Fond of state-of-the-art technology and cutting-edge manufacturing processes, the company is known for its support of a well-known luxury automotive brand in joining the EV revolution.In its quest for the most advanced technology to meet its precision measurement needs, DURA Auto has chosen Creaform for its additional measuring capacity, portability, and flexibility. Armed with the MetraSCAN 3D and HandyPROBE (paired with Polyworks), the engineers can achieve precision tolerances for the most demanding product specifications.<iframe width="640" height="360" src="https://www.youtube.com/embed/uwaPeHpu-NA?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>In addition, the unmatched speed and portability of the measuring instruments contributed to reducing the inspection time, which impacted the overall efficiency of the manufacturing process and the production throughput.&nbsp;We use the Creaform MetraSCAN 3D and HandyPROBE as portable measurement stations to measure incoming extrusions and get quick scans of the product before it moves forward to a mill to ensure the mill will accept the part. Thanks to Creaform, we have increased our capacity by 75%.-Branden Head, Metrology Supervisor at Dura AutomotiveThe distinct performance obtained with Creaform and Polyworks has confirmed their strong reputation in the 3D measurement industry. “Creaform and its 3D measurement solutions were pivotal for the measurement capability in our facility,” adds Mr. Head. “Our project would have struggled with capacity and mobility without Creaform’s and Polyworks’s technology.”&nbsp;&nbsp;Solution: Automated Quality ControlAutomated quality control (AQC) systems are becoming a key strategy for increasing inspection efficiency and production throughput without sacrificing measurement accuracy. No matter the production type—high mix/low volume or low mix/high volume—AQC solutions can be integrated within a production line quickly and without any lengthy training or significant downtimes. They will automatically slash data acquisition times from hours to mere minutes, all while ensuring manufacturers feel confident that the EV parts are approved according to tight tolerances and industry regulations.<a href="https://www.creaform3d.com/en/solutions/automated-quality-control-key-strategy-e-car-manufacturers-speed-their-throughput" target="_blank">Why Walter Automobiltechnik Turned to Creaform</a>Walter Automobiltechnik GmbH is a renowned German part and accessory supplier for big OEMs in the automotive and motorcycle industries. Over the past few years, skyrocketing demand from OEMs for new EV parts drove the company to look for an alternative inspection approach to improve its part quality and productivity. In particular, Walter Automobiltechnik wanted a solution to replace its manual methods and traditional CMM in producing an EV engine mount for BMW’s new fully electric Mini Cooper SE.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1702552632466-000035.webp" style="width: 300px;" class="fr-fic fr-dib">Looking to assess the quality of its EV engine mounts and maintain a short cycle time, Walter Automobiltechnik turned to Creaform’s R-Series. The metrology team implemented the MetraSCAN 3D-R, a powerful robot-mounted optical scanner, into two custom, automated industrial measuring cells at the end of the production line. VXelements, Creaform’s fully integrated 3D software platform, was also chosen to conduct the inspections.With the MetraSCAN 3D-R’s high measurement rate, Walter Automobiltechnik drastically reduced its inspection time from one hour and 30 minutes to just eight minutes per mount—all with an accuracy of 0.05 mm. Undoubtedly, Walter Automobiltechnik could not have achieved that level of throughput with a traditional CMM. “In the future, we think this system is a must-have in the automotive industry,” said Tommy Laukdrej, Head of Quality Management at Walter Automobiltechnik.Faster Inspection Time for Higher Production ThroughputAny proven and trusted method that accelerates inspection time will lead to higher production throughput. Whether automotive parts manufacturers are performing inspections directly on the shop floor or automating the inspection process without compromising on accuracy, they have everything to gain from considering portable or automated 3D scanning solutions. On top of that, their increased efficiency will greatly please their customers.

Based on the latest International Energy Agency (IEA) projections (featured in the newest edition of the Global EV Outlook), the share of electric vehicles (EVs) in the overall car market has risen from around 4% in 2020 to 14% in 2022 and is set to increase further to 18% in 2023.

Electric Dream: The Booming Popularity of Electric Vehicles and What It Means for Automotive Part Manufacturers

<a href="https://www.gfcs.com/" target="_blank">GF Casting Solutions Altenmarkt GmbH &amp; Co KG</a> is one of the leading solution providers for lightweight components in the mobility and energy sector and operates, among other things, a light metal foundry for automotive components, structural parts and powertrain parts that are manufactured using the aluminum and magnesium die-cast process. One of three divisions of Georg Fischer AG, the company draws on 200 years of expertise and has 13 locations in Germany, Austria, Romania, Switzerland and China.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1701942963549-GF_scanning_1-1536x1024.webp" style="width: 766px;" class="fr-fic fr-dib">With these products becoming more and more complex and versatile, the GF Castings Production Control Department in Austria is tasked with checking repairs during ongoing production – as best as possible and in the shortest possible time.Previously, measurements were carried out in the measuring room using a GOM system. However, since the measuring room was often busy, it sometimes meant that they needed to wait several hours for their turn, and thus for the result of measurements. This led to the decision to purchase a 3D hand scanner for Production Control. The aim was also to expand the field of activity of employees in Production Control to include measurement technology tasks. The choice fell on the <a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d" target="_blank">Go!SCAN Spark</a> from Creaform.The scanner was easy to implement and employee acceptance was high. A total of 4 colleagues from the Production Control team were trained to operate the 3D scanner and evaluate the acquired data.<h2>Where is the Go!SCAN 3D used?<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1701942946855-GF_scanning_2-1-1536x1024.webp" style="width: 766px;" class="fr-fic fr-dib">Go!SCAN SPARK scanning a casting. The acquired data is displayed in real time in the 3D metrology software.</h2>At GF Casting Solutions, the Go!SCAN SPARK in combination with the <a href="https://www.creaform3d.com/en/metrology-solutions/vxinspect-dimensional-inspection-software-module" target="_blank" id="isPasted">VXinspect Elite</a> 3D metrology software is used directly in production. Its areas of application are:<ul><li>Measurement of repaired mold breakouts in ongoing manufacturing.</li><li>Quick analysis measurements where there are deformations.</li><li>Analysis measurements in the course of key projects (e-machine).</li><li>Scanning from and return to CAD of simple components.</li></ul>GF believes that using the 3D scanner in Production Control helps reduce the costs associated with rejects, to produce higher quality parts while at the same time minimizing inspection time.According to GF, the Creaform software platform also offers a distinct advantage:“The VXinspect Elite Module of the VXelements Suite is the only software that can do everything from scans to reports. It is easy to use and there is no need to switch between different applications. This not only saves time, but also makes the application intuitive, since all the control elements look the same in all the modules. The VXinspect Elite module is also a NIST-certified inspection software and has all the necessary functions required by ISO and ASME for first-sample testing, quality control and quality assurance during the manufacturing process.”<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1701943006290-GF_scanning_3-1536x1024.webp" style="width: 766px;" class="fr-fic fr-dib">Evaluation of the scanned component using CAD comparison with color matching in the VXinspect softwareChristoph Forster, Quality Engineer / AL Production Control at GF Castings Solutions, explains: “The Go!SCAN SPARK can scan immediately without any prior setup and offers excellent geometry and texture acquisition. Most objects can be scanned in minutes and a comparison can be made with the existing CAD model. No preparations such as spraying the components or sticking on reference marks are required. I can personally really recommend the Creaform system because of its easy operation and the highly intuitive software that includes many options – and Creaform’s support is also very good and competent.”<a href="https://www.creaform3d.com/blog/pun5th75ef_wp/wp-content/uploads/Logo-GF.jpg" target="_blank" rel="https://www.gfcs.com/de.html noopener"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1701943031908-Logo-GF-300x95.webp" style="width: 300px;" class="fr-fic fr-dib"></a>

Go!SCAN SPARK scanning a casting. The acquired data is displayed in real time in the 3D metrology software.

Portable 3D scanner relieves measuring room workload and reduces downtime in production

Production Control in the Casting Industry: Ensuring Component Geometries

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

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

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

Do You Have Trouble Measuring and Analyzing Large Parts?

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

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

Electrifying the future with 3D scanning technologies

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

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

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

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

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

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

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