3D SCANNING PROCESS

MSME TOOL ROOM

INDO GERMAN TOOL ROOM, AURANGABAD

AN ISO 9001:2008, 14001:2004 CERTIFED TOOL ROOM AND TRAINING CENTRE

A GOVERNMENT OF INDIA SOCIETY, MINISTRY OF MICRO, SMALL AND MEDIUM
ENTERPRISES.

PROJECT REPORT
ON

3D SCANNING PROCESS
(LH ENGINE BRACKET)

SUBMITTED BY
Manali Gawai (190051913)
Nitin Jaid (190051942)
Nakul Gaikwad (190051958)

IN PARTIAL FULFILLMENT FOR THE AWARD PGDTD&CC TO INDO GERMAN TOOL

ROOM, AURANGABAD.

JULY 2019 – OCTOBER 2021

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MSME TOOL ROOM

INDO GERMAN TOOL ROOM, AURANGABAD

AN ISO 9001:2008, 14001:2004 CERTIFIED TOOL ROOM AND TRAINING CENTRE

A GOVERNMENT OF INDIA SOCIETY, MINISTRY OF MICRO, SMALL AND MEDIUM ENTERPRISES.

CERTIFICATE
THIS IS TO CERTIFY THAT THE PROJECT REPORT ENTITLE

3D SCANNING PROCESS
(LH ENGINE BRACKET)

THAT IS BEING SUBMITTED BY

Manali Gawai (190051913)

Nitin Jaid (190051942)
Nakul Gaikwad (190051958)

PARTIAL FULFILLMENT FOR THEAWARD OF CERTIFICATE OF

POST GRADUATE DIPLOMA IN TOOL DESIGN & CAD-CAM

TO THE MSME TOOL ROOM, AURANGABAD IS A RECORD OF BONAFIRE WORK
CARRIED OUT BY THEM UNDER OUR GUIDANCE AND SUPERVISION IN
ACEDEMIC YEAR OF

JULY 2019 TO OCTOBER 2021

HEAD OF DEPARTMENT COURSE COORDINATOR SIGN OF GUIDE

Mr. Arnab Bhattacharya Mr. Ganesh Rupnar Mr. Sudhanshu Sahu

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Acknowledgement

I find this as a great opportunity at the completion of course Post

Graduate Diploma in Tool Design & CAD-CAM while submitting this
report to express our sincere regards and vote of thanks to Mr. Arnab
Bhattacharya and all the faculty members at Indo-German Tool Room,
Aurangabad, who directly or indirectly made their contribution for success of
our course.
I also take this opportunity to thank Mr. Sudhanshu Sahu for his
guidance and assistance in completing the final project.
At the end we would like to thank all the staff of IGTR for their hearty
support.

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Index

1. Abstract 6
2. Synopsys 7
3. Introduction 8
4. Standard Operating Procedure 4
A. Scanning Process 12
1) Calibration 12
2) Pre-Processing 13
3) Scanning 13
4) Post-Processing 15
B. Analysis 16
1) Import Data 16
2) Pre-Alignment 16
3) Alignment 18
4) Surface Comparison 22
5) Deviation Flyers 25
5. Conclusion 26
6. Report 26

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List of Figures
Fig 1. Comet 8
Fig 2. Projector Lens 9
Fig 3. Camera Lens 9
Fig 4. Calibration Plate 9
Fig 5. Calibration Template 10
Fig 6. Markers 10
Fig 7. Developer Coated Component With Markers 13
Fig 8. Scanning Process 14
Fig 9. Post Processing 15
Fig 10. Global Optimization 15
Fig 11. Work Environment 16
Fig 12. Manual Pre-Alignment Process 17
Fig 13. Manual Pre-Alignment Result 17
Fig 14. Best Fit Alignment Process 19
Fig 15. Best Fit Alignment Result 19
Fig 16. RPS Alignment Process 21
Fig 17. RPS Alignment Process Result 22
Fig 18. Surface Comparison Process 23
Fig 19. Surface Comparison Result 23
Fig 20. Edit Color Table 24
Fig 21. Deviation Flyer 25

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Abstract
3D scanning process is a revolutionary modern-day technique used for two
widely used domains of product development and quality control. 3D scanning
technique imparts ease in doing the required activities in these domains with
high level of accuracy as compared to the conventional methods of doing the
same job.

In product development 3D scanning process can be used for reverse

engineering process to generate a 3D cad model from the actual physical model
which can be used for the development of new product. Where as in case of
quality control department 3D scanning process can be used for the comparison
between the manufactured product and the cad model of the same product. This
comparison made at the surface level gives the highly accurate imaging of the
dimensional mismatch between the actual product and CAD file.

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Synopsis
Aim of this project report is to describe the activities done during the duration of
internship done at Indo-German Tool Room, Aurangabad. The project is
primarily process oriented than the product oriented. Project report focuses on
the method and steps involved in 3D scanning process of a machined component
& and process of surface comparison between scanned and cad data. Report
generated by the help of Inspect plus software is the final conclusion of the
project.

Steps involved in the activity are as follows.

1. Selection of lens.
2. Preprocessing of the component.
3. Scanning of the component.
4. Post processing on scanned data.
5. Surface comparison.
6. Report generation.

This six-step process is elaborately explained in the further report with actual
images captured during the scanning process.

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Introduction
3D scanning is a process which provide the user with extremely accurate measurement and
ability to fully utilize, visualize and modify data with cad. The ability to rapidly capture high
accuracy information means vast savings in productivity and time. Process is also known as
blue light scanning as the projector lens projects blue color light on the object.

Component (Hardware) setup to carry out the process consist of following object.

1. Comet
2. Projector lens
3. Camera lens
4. Calibration plate
5. Calibration template
6. Marker stickers
7. Developer solution
8. Cleaner solution

These components are explained briefly as follows.

1. Comet :- Comet is the main unit of the whole setup which contains all the image
processing hardware installed in it. Camera lens and projector lens are also installed in
the slots made in the comet and hence comet can be termed as the primary component
of the setup.

Fig. 1:- Comet

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2. Projector Lens :- Projector lens project the blue light on to the object which is then
captured by the camera lens and then processed further.

Fig. 2:- Projector lens Fig. 3:- Camera lens

3. Camera Lens :- Camera lens captures the images of the object and its then further
processed. Both camera and project lens comes as a set and depending upon the area
covered by the lens they are differentiated as 45mm, 75mm, 250mm, & 500mm.
4. Calibration Plate :- whenever a different set of lenses is installed on the comet
calibration of the lens Is to be done. Calibration plate is used to do so.

Fig. 4:- Calibration Plate

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5. Calibration Template :- calibration template is the template which has specified

lines of various inclinations. Calibration plate aligned along these line one by one to
complete the calibration process.

Fig. 5:- Calibration Template

6. Marker Stickers:- marker stickers are the stickers with a solid black circle
surrounded by a hollow circle with black out line. These stickers are put on the object
and are used to align the images capture from different orientation into a single 3D
object.

Fig. 6:- Markers

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7. Developer Solution :- Developer solution issprayed on to the object which is tobe

scanned. This is a liquid based powder solution which dries after spraying and thus
creates a uniform layer on the surface of the object.
8. Cleaner Solution :- this is the solution used to clean the object before and after the
scanning process. This solution is required to clean the surface from any dirt and oil
that might have stick to the surface during manufacturing process.

Other than these hardware components two softwares are also used during the process.

1. Colin 3D:- Colin 3Dis a software which is integrated with the comet. images
captured by the comet can be seen using this software. This software also gives access
to the user to control the comet as well as to check and align the captured image
during the process. Also, postprocessing and clean-up activity is done using this
software only.
2. Inspect Plus:- this is the software which imports the cad and scanned data on the
same work environment. Using this software scanned and cad model are superimposed
on to one another. This process is termed as alignment.

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Standard Operating Procedure

A] Scanning process

1) Calibration
1. There are 4 types of lenses for scanning i.e., 45mm, 75mm, 250mm, 500mm. Select it
according to the job size.
2. Set camera lens and projector lens of same size at right and left side of the scanner
respectively.
3. Power-on the scanner.
4. After setting lens, set the calibration plate parallel to the focus.
5. We have two types of calibration plates according their size viz., 100mm and 300mm.
6. After completing above setting start ‘COLIN 3D’ software
7. From file menu, select ‘setting’.
8. Select device and equipment option. And set the standards as follows:
a. Categories - Comet
b. Sensor configuration - select your lens size.
c. Calibration plate - select plate size.
d. CAN-BUS adaptor - COMET powerpack.
e. Operating mode - default.
f. Positioning system - No positioning system.
g. Click on ‘OK’.
9. From file menu select ‘new project’.
10. From left side top corner select option - ‘Enables the creation of a new service project
for the selected service’.
11. Then from 3 options, choose ‘calibration’.
12. Set the points on calibration plate and set accordingly to line type P (1 to 9) and
rotation type A, B, C, D.
13. Start measurement.
14. After each cycle completed, click on ‘next’ and after setting ‘start measurement’.
15. After all measurements completed, click on ‘calculate calibration’.
16. This window will give the accuracy attained during the calibration process, click ‘Ok’

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2) Pre-Processing
1. Clean the component with the help of cleaner solution to remove any oil residues or
dirt on the surface of the component
2. Paste the marker sticker on the various surfaces of the object (only flat surface)
3. Make sure that at least four markers will be visible in the single shot.
4. Apply the developer evenly on all the surface area of the component.
5. Clean the markers (remove the developer from the markers)
6. Make sure while cleaning the markers, developer only form marker is removed and
developer form the object surface is untouched. developer form the object surface is
untouched.

Fig. 7:- Developer Coated Component With Markers

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3) Scanning
1. Once the calibration process is completed, select new project from file menu.
2. Click on ‘+’ sign.
3. From left top corner select option ‘enables the creation of a new measurement
project’.
4. Wait for sensor temperature to get into the calibration temperature range or the arrow
turns greens
5. Tick on marker measurement.
6. select COMET and adjust lens according to the job. Make sure complete component is
visible and sufficient markers are visible
7. click on ‘Next’ to take a snapshot of the object.
8. After shot is taken click ‘Next’ and check the image in 3D viewer.
9. Repeat the steps 6-8 with changing the orientation of the object with respect to the
comet until every surface of the component is captured.

Fig. 8:- Scanning Process

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4) Post-Processing
1. After capturing complete component, click on ‘lasso selection’.select and trim the
unwantedbackground which also gets captured along with the target object.
2. Click on ‘data processing’and select ‘global optimization’ and click on start.
3. Click on ‘Mesh Creation’.
4. To save file, go to ‘export’ from file tab and save as STL format
5. This file is to be transferred to the Inspect Plus software.

Fig. 9:- Post-Processing

Fig. 10:- Global Optimization

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B] Analysis Process

1. Import Data
1. Open the Inspect Plus software
2. Drag the CAD Data in IGS file format to the section of ‘Nominal Data’.
3. Drag the Scanned data In STL file format to the section of ‘Actual Data’

Fig. 11:- Work Environment

2. Pre-Alignment

I. Manual Pre-Alignment
At manual Pre-Alignment the actual data are transformed to the nominal data by
using (at least three)corresponding point pairs. It is essential to identify points both in
nominal and actual data and to mark itwith mouse clicks on the objects. The procedure
defines only a rough Pre-Alignment which can beimproved by using one of the
algorithms. Please consider that this alignment is notavailable in viewer mode. The
manual pre-alignment procedure can be subdivided into the followingsteps:
1. The top of the viewer window shows several tabs (see picture above).
2. Select vertical split viewer (see figure below).
3. The nominal data and theactual data are then displayed separately.

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4. Adjust the views of the nominal and actual scenes in such a way that they
bothhave thesame position and orientation in the viewer windows (the data are
nevertheless still in different.
5. Select a point by clicking on the surface of nominal data and select the same
point (approximately) on the Actual Data.
6. Repeat this process at least 4 times
7. Click ‘Ok’.

Fig. 12:- Manual Pre-Alignment Process

Fig. 13:- Manual Pre-Alignment Result

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II. Automatic Pre-Alignment

At automatic pre-alignment four possible alignments to transform actual data to the
nominal data arecomputed in INSPECT Plus. The user is able to switchbetween the
suggested alignments interactivelyand can select the best fitting transformation. The
procedure is only a rough pre-alignment and can beimproved by using an algorithm.
Please consider that the automatic pre-alignmentisnot available in viewer mode.
The automatic pre-alignment is started by selecting Alignment - Automatic
Pre-alignment at themain menu or by using the toolbar. At the beginning the user selects the
involved scene object in thescene selection dialog (see picture below). By clicking OK button
at the scene selection dialog, the nextstep in automatic pre-alignment follows.

3. Alignment
I. Best Fit Alignment
Best fit alignment is an automated alignment type in which software intelligence
aligns the actual and nominal data with best possible way automatically. This the easiest way
to align the data. But at the same time the result obtained by this method of alignment may
not be accurate and thus other type alignment is to be done necessarily.

Steps for the best fit alignment are as follows

1. Open INSPECT PLUS software.

2. In nominal data select CAD model (.igs, .xt ).
3. In actual data select SCAN model as scanned previously (.CTL ).
4. Arrange both the data approximately at the same view.
5. From alignment bar select ‘manual pre alignment’.
6. Make coordinate points at same position on both models and click ‘align’ and then
‘ok’.
7. Again, from alignment bar select ‘best fit alignment’ and click on ‘start’.
8. Best fit alignment done.

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Fig. 14:- Best Fit Alignment Process

Fig. 15:- Best Fit Alignment Result

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II. 3-2-1- Alignment:

As said in the best fit alignment it is not always accurate and hence need of other
alignment method is generated. In order to compensate this 3-2-1 Alignment can be
incorporated. This alignment uses 3 planes, 2 vectors, and one point on the actual data and
same set of geometry at the same location on the nominal data. By aligning the planes vectors
and point from actual data to their respective counterparts on the Nominal Data whole
component gets aligned.

Though this method gives more precise result than Best-fit Alignment, it does have its
own drawback. Very first drawback is this type of alignment is only possible f the component
has three mutually perpendicular faces. If not this method cannot be used.

Steps for 3-2-1 Alignment are as follows

1. Firstly, do the best fit alignment.

2. Hide the actual (scan) data.
3. Click on ‘create plane’ and make 3 planes on X, Y and Z axes respectively by clicking
points on planes.
4. Select any 2 planes and click on ‘create vector’.
5. Select all 3 planes and click on ‘create point’.
6. Then create the same features (plane, vector, point) on nominal data at the same
positions as the actual data.
7. Remember the vector direction must be same.
8. Click on plane, vector and point one by one and from properties option give it
correspondence.
9. From alignment bar select ‘3-2-1 alignment’.
10. Check all existing plane, vector, point. And click ‘ok’.
11. 3-2-1 alignment is completed.

Note :-As the component on which we are working does not have three Mutually
Perpendicular surfaces thus it is not possible to do 3-2-1 Alignment and therefore only Best fit
Alignment and RPS Alignment are done.

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III. RPS (Reference Point System) Alignment:

As discussed in 3-2-1 Alignment it is not possible in absence of three mutually
perpendicular planes. Hence in such case RPS Alignment is used. RPS Alignment,
located under the Alignment tab, is the alignment of Actual and Nominal object by
declaring a set of corresponding points on each, and by constraining each pair of
points in a single direction.

Steps for RPS Alignment are as follows.

1. Firstly, do the best fit alignment.

2. Hide the actual (scan) data.
3. Click on ‘RPS point’ and take RPS points on X, Y, Z planes on CAD model.
4. Show both the data.
5. From alignment bar click on ‘RPS alignment’.
6. Select start.
7. RPS alignment is completed.

Fig. 16:- RPS Alignment Process

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Fig. 17:- RPS Alignment Result

4. Surface Comparison

After the alignment of the actual and nominal data comparison between the two is done. The
comparison is done at the surface level which is done by the command surface comparison.
In a surface comparison, all surfaces of the models you want to compare are compared with
one
another. The deviations are displayed as color values on the surface of the actual data. The
magnitude
of a deviation can be determined from the color table which you find on the left-hand side of
the viewer.

Steps for Surface comparison are as follows.

1. Ensure the alignment is completed by either of Best fit, 3-2-1 or RPS method.
2. Select ‘comparison’ from menu bar
3. Select ‘surface comparison’.
4. Select nominal and actual data in their respective fields.
5. Select the color table.

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Fig. 18:- Surface Comparison Process

6. Click ‘OK’

Fig. 19:- Surface Comparison Result

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Steps for editing color table.

1. Select ‘comparison’ from menu bar.
2. Select ‘Edit Color Table’.
3. Select the upper and lower tolerance limit. (Positive & Negative).
4. Select the number of steps in which tolerance zone is to be divided.
5. Assign a specific color to each step.
6. Usually Red for maximum material condition and Blue for Minimum Material
Condition and Green for zero Deviation.

Fig. 20:- Edit Color Table

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5. Deviation Flyers

Deviation Flyers shows the amount of deviation between the dimensions of the Actual
and Nominal Data at the selected point
Steps for creating deviation flyers are as follows
1. Complete the surface comparison
2. Hide nominal data
3. Go to ‘create flyer’
4. Select ‘deviationflyer’
5. Click on the point on actual data at which deviation in the dimension is to be checked.
6. Deviation flyer is created.
7. Repeat the process until all required deviation flyers are created

Fig. 21:- Deviation Flyers

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Conclusion
From the above surface comparison, a final report is generated and sent to the respective
department. With reference of the result further decision to accept, reject or to rework the
component can be taken by the concerned authority. The report consists of following details
1. Images of CAD file and Scanned file.
2. Images of alignment
3. Images of surface comparison. (Multiple images to cover all the surfaces of the
component).
With this report, the scanning processcan be said to be completed. The report generated
using ‘Inspect Plus’ software is as follows.

Report
(Generated through ‘Inspect Plus’ Software)

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