Blog – Scansite

3D Scanning and Classic Automobiles

David Bassett — Tue, 24 Oct 2017 01:49:51 +0000

October 23, 2017

Author: Somerset Bassett

At Scansite3D, we have seen a marked increase in interest from legacy automobile owners. 3D scanning has fully captured the imagination of the classic car community and for good reason, too! It was 25 years ago that Scansite3D milled its first buck from scan data; and we still mill them, but now we also 3D print replacement parts and even redesign entire engines using the scan data as a starting point.

The growth of rapid prototyping technologies such as 3d printing and the ability to CNC parts in metal with high precision, have vaulted scanning technology to the forefront. Scansite3D has been creating extremely accurate scan data for some time, but now more than ever, machine shops and manufacturers have multiple options to utilize it. In other words, the industry is catching up!

The applications for using 3D scanning on classic cars are varied and growing rapidly. Uses include making replacement parts, repairing broken components or simply documenting the as-built condition of the automobile. And let’s not forget – buck making and sheet metal fabrication! Scanning and reverse engineering facilitates efficiency improvements, inspection, easier production, and even the ability to change materials to create lighter or stronger parts.

However; just like the restoration of a classic car, the success of a project rests entirely on the process and all scanners are NOT created equal. Reproducing a windshield, for instance, which matches the exact dimensions of an existing part, which was made by hand, can only happen if you start with a highly accurate 3D scan. Otherwise, errors that are inherent with inferior data will ‘stack’ and the results can be disastrous.

At Scansite3D, all our scanners are Aerospace certified and our engineers and support staff are the most experienced in the business. Spending time and money on a poor scan, and then manufacturing parts from it, can be a frustrating and expensive experience. Those who bring their engineering projects to Scansite3D, receive 25+ years of scanning and engineering know-how, as well as, the deep understanding of how to use the data once it goes out the door.

3D scanning engine compartment of 1953 Jaguar C-Type with structured light scanner

Reverse Engineering Legacy Parts for 1938 Talbot Lago

David Bassett — Wed, 05 Apr 2017 19:18:48 +0000

Author: Somerset Bassett

The 1938 Talbot Lago bevel gear we were asked to reverse engineer required a CAD file to create new parts. These parts wear over time and the originals have not been supported since Lago was sold in 1958. We began by scanning the object with an aerospace grade Breuckmann optical scanner which captures every detail, including the wear, to within 10 +/- microns. From there, the data is transformed through the use of several CAD (computer assisted design) packages. Beginning as an .STL file, which has severe limitations in CAD and CAM software, the data results in a parametric CAD file which can be used in all state of the art design and manufacturing processes. Because of the accuracy of our scanners and accruement of our engineer team, our files are often determined to be better than the original parts.

Many companies do not support their past models with replacement parts, even if the product is still in high demand. This happens for many reasons; companies change hands, drawings and molds are lost, and businesses go under. Mechanics and enthusiasts often anticipate these issues and stock up on many essential parts. Other items, unfortunately, have become increasingly scarce which is why we are called upon to recreate these historic parts.

This is not an uncommon problem. The best example being the A-10 Warthog, a military plane that specializes in close combat air support for ground troops. Prior to the second Gulf War, the plane had been retired and, in classic military fashion, the manufacturing molds were destroyed. However; as the slow speed of the plane made it a favorite of ground troops, the last 10 vehicles in working condition were in extremely high demand. The military contracted extensive 3D scanning and reverse engineering work to recreate functional molds to make replacement parts for those that were worn out or destroyed in combat. With the help of 3D scanning and skilled CAD and CAM work, the planes can continue to support the troops.

Did your project get outsourced?

David Bassett — Wed, 15 Jun 2016 00:10:49 +0000

The Problem with Overseas CAD Work.

Author: Somerset Bassett

Increasingly, one of the problems with globalization is that vital intellectual property information is traveling over great distances with minimal oversight. And many companies do not feel obligated or inclined to share where your data is being sent or stored.

Whether you are receiving technical support, making online purchases, or collaborating with oversees partners your information is at risk. Intellectual property laws have not yet come to grips with our “flat world”, and economic inequality provides a great incentive for people paid much less than their western counterparts to share data to improve their circumstance.

Some of these breaches in security are very well publicized such as last year when customers from Home Depot found their credit information had been stolen and was being sold online for $1 each. And we all know that no matter how rich your previously unknown great uncle was, it is unwise to send your bank information to his estate in Nigeria! But we are more vulnerable than we know.

In 2003, a developer for an Indian programming firm was caught trying to sell the source code of CAD software maker, SolidWorks, which his company had a contract with. The cost for the intended sale was negligible; however, in a country where the average worker makes $450 USD, the sum surely seemed life changing. Intellectual property, if stolen, is a genie that can’t be put back in the bottle and there are no enforced laws to protect American companies’ intellectual property.

At Scansite 3D, we understand the risks and have taken strong measures to ensure that all data produced is secure and 100% of our 3D scanning, 3D metrology, reverse engineering, inspection and CAD work is done entirely in the United States by certified, competent and vetted engineers.

At Scansite we pride ourselves…..

The Importance of High Quality 3D Scan Data – Ours versus Theirs – Episode #1

David Bassett — Tue, 08 Dec 2015 03:45:59 +0000

When commissioning 3D scanning services, its crucial to know what the “downstream” application will be. Will the 3D data be used for reverse engineering? 3D printing? CNC milling? Visualization? FEA or CFD? While some downstream applications are more forgiving than others, one thing is clear: Getting the best high quality 3D scan data available will greatly increase your chances for success.

In general, medium to large size, “soft”, organically shaped objects are the easiest to scan. Objects with sharp edges, and/or small features – including the majority of industrial objects – are much more challenging and require higher quality hardware and more experienced operators. These are among the projects that simply can’t be done in a satisfactory manner with low end scanners.

Scansite 3D uses aerospace certified structured light scanners manufactured by GOM/ATOS and Aicon/Breuckmann, as well as the entire suite of Creaform 3D scanners, and Aicon3D Photogrammetry systems. We have top quality hardware and software, and experienced, talented people doing our scanning, and we are proud of the 3D data we produce.

It often happens that we see 3D data produced by other people using other scanners. Frankly, we are often surprised at the poor quality of some of this data and what apparently passes as “standard” in our industry. I’ve concluded that the majority of the consumers of 3D data don’t really know what good and bad data looks like, and what they can expect to receive for their money.

Hence the mission of this blog edition – the first in an ongoing series – is to show examples of high quality versus poor quality scan data – and hopefully educate the 3D data consuming public.

Below are two examples of 3D scan data. Both are computer screen shots of .stl (polygon mesh) 3D scan data. Please “click to enlarge” these screen shots to get a good look at the quality of the data.

“Industry standard” 3D scan data (Click to enlarge) . This 3D data was professionally scanned using a mid-range, non-structured light scanner. Note the softness of the features. The screw heads and other features appear to have “melted”.

Structured light scanned data (Click to enlarge) . This automobile carburetor was scanned at Scansite 3D’s studio using a Breuckmann StereoScan “white light” (or “structured light”) scanner. Note the crispness of the screw heads. Sharp edges remain sharp.

If this data is used for building a CAD file in reverse engineering software, our engineers can be confident that the resulting geometry will be accurate within precise tolerances.

Finally, let’s suppose that the “downstream” application for the two data sets shown above is reverse engineering. The CAD engineer will attempt to build a CAD file by extracting features from the scan data. Which data set would yield the more accurate CAD data? You decide!

3D Scanning a Salt Flat Racer for Speed Performance Adjustments during Speed Week

David Bassett — Wed, 15 Jul 2015 15:48:24 +0000

Project:
3D scanning an LSR Streamliner to make performance improvements before Speed Week at Bonneville.

Challenge:
In order to investigate potential modifications, HELIMEC needed to scan the vehicle onsite so that a computer model could be created for CFD analysis.

Solution:
With Scansite 3D’s extensive experience, HELIMEC received the detailed information needed and was able to determine if changes were feasible.

HELIMEC, a product design firm, needed to 3D digitize a salt flat racer to perform computational fluid dynamics to analyze performance and streamline aerodynamics. Read the full case study.

Driving Performance
The company needed to 3D digitize the Mariani salt flat racer to perform computational fluid dynamics (CFD) in order to analyze performance issues and streamline the car’s aerodynamic profile. HELIMEC chose Scansite 3D to do the 3D scanning and CAD file creation.

“It was an easy choice for us since we’ve used Scansite 3D for other projects and they’ve done phenomenal work,” said Andrew Greene, HELIMEC. “Scansite 3D provides us with the tailored detail we need to create the models required for analysis. Scansite 3D is highly accurate and David (Scansite 3D CTO) has the specific, extensive expertise that we need. Scansite 3D is easy to communicate with and they always understand and deliver what we want.”

“Scansite 3D provides us with the tailored detail we need to create the models required for analysis. Scansite 3D is highly accurate and David (Scansite 3D CTO) has the specific, extensive expertise that we need.” — Andrew Greene, HELIMEC

Unlike some companies, Scansite 3D is able to deliver onsite services, so the company went to Mariani’s facility to 3D scan the car. Once the car was digitized, Scansite 3D precisely edited the data by using the surrounding topography as a guide to fill in any missing information to ensure the best 3D data possible.

Virtual Road Testing
Once this step was complete, Scansite 3D then worked to create high tolerance STEP files, parametric file formats needed by the Computer Aided Design (CAD) program to run the CFD tests. HELIMEC ran these tests repeatedly with computerized modifications to the car, a virtual model if you will, to find out if the car’s performance would improve with the aerodynamic design changes.

“There is a lot more work involved in going from 3D scan data to a STEP or IGES file, which is what HELIMEC needed for this race car project,” said David Bassett, CTO at Scansite 3D. “We use the best hardware and software available on the market. But getting the raw scan data to a parametric format needed by CAD takes extensive expertise, talent and experience, which is what we bring to our clients.”

“From the scan data and CAD file that Scansite 3D provided, we created a computer model of the car, put it in a virtual wind tunnel and produced results information on drag, turbulence, and more,” said Greene.

Finish Line
As it turned out, the CFD results revealed that it would be best to start over with a new car. “We determined that not enough changes could be made to the existing car to improve its aerodynamic profile enough to compete at the level desired, so a new one was built,” said Greene. “Only Scansite 3D’s meticulous work could give us the details we needed to run all of the tests in the time we needed to run them.”

HELIMEC appreciates the expertise and experience of the Scansite 3D team and the precision of its 3D scanners. “You just know when you talk to Scansite 3D that you’ll end up with accurate, usable data, and once you’ve used Scansite 3D, you’ll use them the next time,” said Greene. “In any development effort, if you rely on a vendor and it doesn’t work out, it can be difficult to recover the lost time and costs. Scansite 3D takes the time to understand our particular needs for each unique set of problems and they always deliver on time. And, finally, it doesn’t hurt that Scansite 3D is a team of awfully nice people.”

“In any development effort, if you rely on a vendor and it doesn’t work out, it can be difficult to recover the lost time and costs. Scansite takes the time to understand our particular needs for each unique set of problems and always deliver on time.” — Andrew Greene, HELIMEC

Scansite Provides 3D Scans of Rodin’s Hands for Stanford’s Division of Clinical Anatomy

David Bassett — Sat, 06 Jun 2015 15:01:17 +0000

For an accurate representation of these detailed sculptures, with their many nooks and crevices, Stanford University
needed a scanning provider that could deliver extremely high quality 3D scans. Using Three Dimensional Sculptures to Demonstrate and Train Clinical Anatomy and Surgical Students at Stanford University Medical Center, Scansite Provides 3D Scans of Rodin’s Hands for Stanford’s Division of Clinical Anatomy

Read the PDF case study here. Scroll down or right-click to download.

3D Scanning Restores and Replaces Crumbling Courthouse Sculpture

David Bassett — Tue, 01 Oct 2013 02:04:41 +0000

Scansite 3D used 3D scanning and custom editing techniques to provide crucial steps in restoring a historic Santa Barbara fountain.

The Spirit of the Ocean, Santa Barbara’s iconic and seemingly robust fountain, has been crumbling for decades and is on the verge of collapse. The chosen remedy, after years of discussions and planning, was to replace the sculpture.

News Item: 3D Scanning and Custom Editing Restore and Replace Courthouse Sculpture

The next big step in the replacement process was to obtain a three-dimensional scan of the existing sculpture, and Lisa Federici and David Bassett of Scansite 3D were in town to complete that step. The 3D scanning process creates a 3D point cloud or polychrome of the surface in the modeling software. The task was finished Tuesday night an hour before midnight. Bassett and Federici placed evenly spaced registry dots on the sculpture and then proceeded to scan, section by section, the entire accessible surface of the sculpture. They performed about 30 scans, each taking 10 to 15 minutes.

The scan wasn’t conducted in the dead of night to hide the process. Dark is just the obvious and best time to gather data that relies on controlled light sources. A plywood platform was built for the scanner equipment and personnel. The protective plastic sheet that has shielded the sculpture from this season’s weather was removed. Several palm-sized shards from the dolphin-fish head, knocked off by a child climbing on the statue in June, were set aside.

Bassett expects up to 10 days of further manipulation of the scanned images in the software. He traverses the images “patch by patch, spline by spline,” ensuring a file that can be used as both an archival record of the sculpture and as the basis for creating a new model for the sculptors to work from.

Scansite 3D’s target with the project is to provide a 3D scanned image as close to the original sculpture as possible. One version of the file will go on record with the county for future reference. One will be sent to Satellite Models of Belmont. Satellite will take the scan file, feed it into a CNC milling machine, load the machine with appropriate-sized foam blanks and set the machine in motion.

Read the complete article about restoring Santa Barbara’s historic fountain

https://archive.is/oxSv

Scansite 3D & AP Proto Team Up to Create 3D Laser Scanning of Sculpture for Notre Dame

David Bassett — Sat, 15 Sep 2007 23:47:23 +0000

Artist Robert Graham recruits Scansite 3D and AP Proto to help him create a new bronze sculpture for the Basilica at Notre Dame University.

Selective Laser Sintering Used to Create Bronze Sculpture for Basilica at Notre Dame University

The additive fabrication process known as Selective Laser Sintering (SLS®) is best known for producing tough, durable parts for rigorous testing and wax patterns for investment casting direct from 3D Computer Aided Design (CAD) data. SLS® has long been a favorite of many designers and engineers and has now found a new proponent in contemporary artist Robert Graham. Historically, Graham has used traditional methods for producing his cast artwork but those methods are known for being slow, laborious and usually result in a loss of some artistic detail. Graham, being the progressive artist that he is, was already using other additive fabrication methods for previous projects and was introduced to the benefits of SLS® technology during his extensive relationship with American Precision Prototyping (APP). Graham was commissioned by the University of Notre Dame to create a 6 foot, full body bronze statue of Father Basile Antoine-Marie Moreau, c.s.c for the Basilica of the Sacred Heart Church at the University. Graham, equipped with the knowledge of a new and improved technology, was faced with the challenge of pursuing this project with traditional methods or with this new additive fabrication process that would not only shorten the project time but would also yield a truer representation of his original sculpture.

Mr. Robert Graham, world renowned Venice, CA artist and sculptor has been creating magnificent works of art since the mid 1960’s. His works have been featured in the Museum of Modern Art in New York City, Museum of Modern Art in Paris, France, Museum of Contemporary Art in Los Angeles and many other galleries and museums around the world. In addition to museum and gallery artwork, Graham has designed, sculpted and created civic monuments, awards and coins, public and private works and has consulted on several architectural projects. Graham, also known for his bas-relief pieces, sculpted the Franklin D. Roosevelt Memorial in Washington, D.C., the Duke Ellington Monument in Central Park in New York City and the Olympic Gateway at the Los Angeles Memorial Coliseum for the 1984 Olympic Games.

Graham’s previous public works were monumental cast pieces and were created with the traditional method of enlargement and casting. Typically, traditional methods begin with a hand sketch of the piece followed by the creation of a maquette which is a smaller, sculpted model. The maquette is then taken and enlarged in clay using manual dimension transfer techniques. This step in the process is expensive, time consuming and typically the artistic detail in the maquette is lost in translation when the larger sculpture is completed. Once the large sculpture has been created to the enduse, desired size, it is then cut into smaller, manageable sections. Those smaller sections are then taken and used to create latex rubber and plater molds from which wax patterns will be produced. Once the wax sections have been molded, they are then taken to the foundry and cast into bronze. Once the parts have been cast into metal they are assembled, welded and a finish patina applied.

Graham had utilized additive fabrication, specifically SLS®, SLA® and Polyjet in the past for smaller statues and wall panels that required no secondary finishing or processes. However, this project was unique because the piece was exceptionally large and had to be cast in bronze. This statue, with its intricate detail and size was a challenge not only for APP but also for Graham. All parties involved were on a tight schedule which left no room for error in any phase of the project.

The University of Notre Dame commissioned Graham to create the statue of Father Moreau in honor of his beatification. Beatification is a process by which a person is granted the title of Blessed by the Holy Father declaring that person a model for Christian life and virtue and is a step towards Canonization or being declared a Saint. This title is only given after an exhaustive study into their life, work and practice of virtue. The original ceremony for Father Moreau was held in Le Mans, France on Saturday, September 15th, 2007. Among the 4000 plus in attendance were the Prime Minister of France and his wife. The statue, required for the ceremony at Notre Dame, was held on Thursday, September 20th. In attendance at Notre Dame were members of the Holy Cross community, the Bishop of Bangladesh, the archbishop of Los Angeles, University President Father John Jenkins and university attendees.

In his quest to keep all aspects of the original sketch true, Graham decided to use the 3D laser scanning method combined with additive fabrication and direct digital manufacturing to have his statue created. 3D laser scanning is a faster, more cost effective path from the maquette to the final bronze. This process also allows for retention of the original artistic detail of the handsculpted maquette, reduces time to casting and ensures the model size is accurate.

Graham contacted Scansite 3D, located in Woodacre, California to perform the 3D laser scanning and data collection. Scansite 3D, an industry leader in 3D scanning, had worked with Graham on several projects in the past. Scansite 3D used an ATOS structured light scanner to collect three dimensional data from the physical object. The surface data of the object is captured to create a dense collection of X, Y and Z points in 3D space. This point cloud can easily be exported to polygonal 3D CAD file that can be used in additive fabrication and direct digital manufacturing. The digitizing source of the ATOS scanner is a halogen bulb which gathers 1.4 million points per second which produces a much cleaner, higher resolution file.

Once APP received the scanned file, it was hollowed to facilitate the casting process which requires a wall thickness of approximately .125”. After hollowing, the file was cut into manageable sections which were then cut into smaller segments that were of an appropriate size to fit into the SLS machine. Each segment had to be scaled to account for differential shrinkage that occurs during the additive fabrication and foundry processes. Flanges and bolt holes were designed into the 3D CAD file to facilitate casting and assembly. After the sections were adequately designed for manufacturing, APP was ready to begin building.

Since this was to be a master pattern for metal casting, APP chose to use the SLS® process and 3D Systems’ CastForm™ PS powder to build each segment. CastForm™ powder, with its low density and low ash content, was formulated specifically for the investment casting process and is a favorite among foundries across the country. The 3D Systems Sinterstation® HiQ™ HS was the machine selected for this project. The HiQ HS has a large build envelope of 15x13x18” and a high-powered laser to facilitate faster builds. Eight builds were scheduled to complete the 28 segments that made up the complete statue which would take approximately eleven days of machine time to complete. Each build, holding 3 to 5 segments required an average of 32 hours each. After each build was finished, the parts were required to cool in the machine for several hours before part removal could begin. Once the parts had cooled, they were carefully removed from the bed of powder and cleaned off to remove excess powder with brushes and delicate tools. Once each piece was completely free of excess powder, it was hand dipped into hot, melted foundry wax for a specific amount of time which was dependent on each segment’s thickness. The part was then removed and allowed to drain and cool. After additional hand work, the segments were complete and ready to be packaged and sent to the foundry.

Wax patterns that are created using additive fabrication can typically be processed at the foundry with the same methods as wax patterns created using traditional methods. The foundry takes the CastForm™ pattern and coats it with several layers of ceramic slurry to form a ceramic shell around the part. Once that shell is hardened, it is put into an autoclave to burn out the CastForm™ wax pattern leaving an empty mold. The empty mold is then placed into a furnace at a temperature of approximately 2000 degrees Fahrenheit to cure. After the mold has cured, additional cleaning is performed to remove any remaining CastForm™ material, ash or other debris. This step is crucial to the success of the cast bronze because any imperfections will result in a bad pour and would destroy the detail of the final cast piece. Molten bronze is then poured into the cleaned ceramic molds creating the cast part. After a cooling period, the ceramic shells are removed via a break-out process. Sprues, gates and runners in the casting must be ground off and the part cleaned up and inspected for any porosity, short feeds or other defects. Segments are assembled into sections and sections are assembled to form the complete statue. One of the last steps in the casting process is to apply a finish patina which gives the casting a uniform finish.

The Notre Dame project was ultimately a success. The benefits of additive fabrication and direct digital manufacturing reduced project time, lowered cost and produced the original artistic detail in the bronze. Robert Graham continues to work with APP on new projects and will continue to utilize additive fabrication and direct digital manufacturing on future projects.

See the PDF of this article Selective Laser Sintering Used to Create Bronze Sculpture for Basilica at Notre Dame University

Robert Graham: The Great Bronze Doors for the Cathedral of Our Lady of the Angels

David Bassett — Thu, 01 Aug 2002 23:25:31 +0000

This insightful book provides an insider’s glimpse into how Scansite 3D helped sculptor Robert Graham create the Vatican’s most ambitious building project since the Renaissance. Spanning over a 2 year period, Scansite 3D used high end 3D laser scanner on tiny, one inch, hand sculpted tiles to produce meticulous 3D data for CNC milling and bronze casting. The resulting files were digitally enlarged a whopping 32 times from their original size!

The book also provides a unique perspective into the world of 3D laser scanning, as told by Robert Graham himself, and gives the reader a glimpse into the creative design process. Reading this book allows one to truly understand the 3D scanning process, as well as, appreciate the beauty and meaning of the Cathedral’s bronze doors. Photographs and technical diagrams are a special treat for readers who like to have the full story!

A multi-year collaboration between artist Robert Graham, Scansite 3D and others is revealed in this fascinating book.

Robert Graham: The Great Bronze Doors for the Cathedral of Our Lady of the Angels, hardcover, by Jack Miles, Peggy Fogelman, Noriko Fujinam

FDR, A Memorial for All of Us

David Bassett — Fri, 12 Jan 2001 06:30:45 +0000

Scansite creates 3D digital files of the new FDR sculpture and bas relief panels for the Memorial in Washington, D.C.

Memorial for All of Us’; Statue of FDR In Wheelchair Added to Tribute

The Washington Post – Washington, D.C.
Author: David Montgomery
Jan 11, 2001

A bronze likeness of a resolute and unashamed Franklin Delano Roosevelt sitting in his wheelchair was unveiled with presidential pomp beside the Tidal Basin yesterday, a powerful and controversial touch added to the 31/2-year-old FDR Memorial.

The refrain on many lips during the ceremony — “He did it all from his wheelchair” — was both a rallying cry for disability rights and a tribute to the president, whose privacy about his condition initially caused planners to omit a depiction of him in the contraption he designed and built with a kitchen chair and bicycle wheels.