Thinking in Reverse

Competitive pressures require organizations to pay close attention to the latest advancements in product design and engineering, even as resources continue to be rationalized.  These factors are increasing the prominence of reverse engineering and scanning technologies with a focus on reducing the amount of time spent translating files from scan data into CAD models, while also improving the accuracy of data generated from physical objects.  A wide array of companies provide hardware and software solutions designed to meet the growing need for reliable and efficient reverse engineering functions.  Here are some notable developments.

Compact Laser Scanner

Weighing just 2.8 lb., with a capacity to complete 18,000 measurements per second, Creaform’s (www.creaform3d.com) MAXscan portable laser scanner has built-in photogrammetric capabilities with unlimited and configurable working volume, eliminating the need for multiple setups.  Data is automatically stored and processed into MAXscan’s reference model in one step, with no external post-alignment required since scans are directly acquired in position in the reference model.  Mesh resolution on complex and detailed surfaces is improved through the use of a decimate triangles slider for scanning of large and very large parts. 

Six-Axis 3D Laser Scanner

Laser Design’s (www.laserdesign.com) WS-Series 3D laser scanners use patented laser line probe technology to scan parts from all orientations—with measuring ranges of up to 1,000 mm in the X-axis, 1,600 mm in the Y-axis and 800 mm in the Z-axis—while rotating data back to a common coordinate system.  Using a Renishaw PH10 probe indexing device, parts can be turned and the underside scanned with all scans being automatically referenced by the scanning software.  The cross-beam design provides for identical thermal reaction in all axes, while the use of self-cleaning and wear-free air bearings improves operational efficiency.   

Advanced Modeling Software

Through the use of its third-generation XOR2 reverse engineering software, Rapidform (www.rapidform.com) claims it can cut CAD model development time by upwards of 30% because solid models are generated directly from the scan data without the need to create separate mesh and surface models.  The software has two kernels, one for handling copious data (i.e., point clouds, polygons and surfaces) and a Parasolid modeler for creating the CAD model. Both data sets are displayed on the screen in the same coordinate space, allowing the designer to immediately detect if the CAD model deviates from the scan data, while at the same time allowing immediate identification and removal of any imperfections.

Laser Scanning Probe

The ability to capture up to 144,000 points per second with digital coordinate output and a class II rating are the primary features of Laserdesign’s (www.laserdesign.com) Surveyor Laser Probes, which feature measurement ranges up to 500 mm.  Dual CMOS receptors, with simultaneous scanning, assist in deep sidewall and recessed geometry capture, while programmable CNC motion control from 3 to 5 axes and in-line applications allow the probes to be individually integrated with any traditional CMM thanks to standard USB data connection capability.     

Tribrid Modeling Capability

Delcam’s (www.delcam.com) CopyCAD Pro is capable of performing Tibrid Modeling , which combines triangle modeling with surface and solid modeling for improved efficiency and data accuracy, through the integration of its PowerSHAPE surface and solid modeling functionality along with its reverse engineering and triangle modeling capabilities.  This integration allows for the creation of improved geometry in areas where only approximate results were available in previous versions through the use of reverse-engineered fillets that display variations in radii, which can be replaced with consistent, smooth fillets. 

Portable Non-Contact Scanner

Using white-light stereo vision technology, CongiTens’ (www.cognitens.com) Optigo RE portable scanner offers adaptive point cloud spacing for improved geometric tracing.  Measured feature dimensions are directly integrated into the 3D model, with the ability to measure dimensions of common closed features (round holes, slots, etc.), cross sections and deviations.  The scanner automatically generates measurement results without the need for point cloud processing, resulting in reduced processing time.

Portable Laser Scanner

Faro’s (www.faro.com) LaserScan Arm V3 7-axis contact/non-contact measuring device offer fully integrated scanning capability with accuracy up to 35 micron with improved warm up time, all while weighing just 370 g.  Using a 660-nm, CDRH Class II/IEC Class 2M laser, the V3 has a scan rate of 30 frames/sec. x 640 points/line, or 19,200 points/sec. with an accuracy rate of 0.0014 in. and a scan width of up to 2.36 in. Built-in Bluetooth wireless connectivity capability enables data transfer without the need for external wiring. 

Rapid Finite Element Meshing

InnovMetric’s (www.innovmetric.com) PolyWorks V11 offers a new optional module that generates quadrilateral meshes directly from digitized models.  The software uses engineering controls, including point pair correspondences and point motion constraints,  to allow users to morph CAD models directly onto triangular models built from the point cloud data.  The morphed triangulations are then converted into quadrangle-dominant meshes that require no triangular editing or NURBS surfacing.