Scribd
Upload
5 views

2

The document discusses the process of 3D scanning and CAD model creation from point clouds, highlighting the importance of these technologies in manufacturing and product design. It details the types of measuring devices, both contact and non-contact, and outlines the steps involved in converting point clouds into usable CAD models. A case study demonstrates the successful implementation of these techniques to reproduce a crucial gearbox housing, resulting in significant time and cost savings.

Uploaded by

charuach18
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
5 views

2

The document discusses the process of 3D scanning and CAD model creation from point clouds, highlighting the importance of these technologies in manufacturing and product design. It details the types of measuring devices, both contact and non-contact, and outlines the steps involved in converting point clouds into usable CAD models. A case study demonstrates the successful implementation of these techniques to reproduce a crucial gearbox housing, resulting in significant time and cost savings.

Uploaded by

charuach18
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 6

Introduction, measuring devicecontact type and non-contact type, CAD model

creation from point clouds-preprocessing, point clouds to surface model


creation.

Detailed Notes on 3D Scanning and CAD


Model Creation from Point Clouds
Introduction
3D scanning and reverse engineering have become essential in manufacturing, product design,
and quality control. These technologies enable the transformation of real-world objects into
accurate digital models. The process involves capturing object data using measuring devices,
processing point clouds, and converting them into a usable CAD model.

3D scanning is used in various industries such as automotive, aerospace, healthcare, and


consumer electronics for applications like:

 Product development and prototyping.


 Dimensional inspection for quality assurance.
 Reproduction of legacy parts for maintenance and repair.
 Medical applications, such as prosthetic design and surgical planning.

Measuring Devices: Contact Type and Non-Contact Type


Measuring devices are categorized into two types based on their interaction with the object:
Contact Measuring Devices and Non-Contact Measuring Devices.

Contact Type Measuring Devices

These devices require physical contact with the object to measure its shape and dimensions
accurately. They are highly precise but may be slow and unsuitable for delicate or soft materials.

1. Coordinate Measuring Machine (CMM):


o Uses a touch probe to collect data points on an object's surface.
o Provides high precision for metrology applications.
o Can be manual, semi-automatic, or fully automated.
2. Micrometers and Calipers:
o Used for small-scale, highly accurate linear measurements.
o Commonly used in machine shops and laboratories.
3. Profilometers:
o Measures surface roughness and texture using a contact probe.
o Used in material science and quality control.
4. Articulated Arm CMMs:
o Portable and flexible measuring devices with a touch probe.
o Used for measuring large objects and complex geometries.

Non-Contact Type Measuring Devices

These devices use light, lasers, or images to capture object dimensions without physical contact,
making them ideal for fragile, soft, or complex surfaces.

1. Laser Scanners:
o Emit laser beams that reflect back to determine surface geometry.
o Generates high-density point clouds.
o Used in automotive, aerospace, and heritage preservation.
2. Structured Light Scanners:
o Project a pattern of light onto the object and measure distortions to map the shape.
o Faster than laser scanning and suitable for capturing detailed textures.
o Used in face recognition, dentistry, and industrial design.
3. Photogrammetry:
o Uses multiple 2D images from different angles to reconstruct a 3D model.
o Requires high-quality images for accurate results.
o Common in architecture, gaming, and VR modeling.
4. Computed Tomography (CT) Scanners:
o Provides both external and internal object structures.
o Uses X-ray imaging for precise internal scans.
o Used in medical diagnostics and industrial defect analysis.

CAD Model Creation from Point Clouds


After data acquisition, the point cloud (a collection of 3D coordinates) must be processed into a
usable CAD model. This involves multiple steps:

Preprocessing

1. Point Cloud Acquisition:


o Data is collected using laser scanners, structured light scanners, or
photogrammetry.
o The output is a raw point cloud in formats like .PLY, .XYZ, .PTS, .STL.
2. Noise Reduction:
o Unwanted points (artifacts from reflections, shadows, or environmental
interference) are filtered.
o Algorithms like Moving Least Squares (MLS) or Statistical Outlier Removal
(SOR) are used.
3. Alignment and Registration:
o Multiple scans of an object are combined into a common coordinate system.
o Techniques like Iterative Closest Point (ICP) ensure precise alignment.
4. Resampling and Smoothing:
o Reduces excessive data points while retaining the object's shape.
o Used for optimizing file sizes and improving processing speed.

Point Clouds to Surface Model Creation

1. Mesh Generation:
o Converts the point cloud into a triangulated mesh (STL, OBJ formats).
o Mesh generation software like MeshLab, Geomagic, or Blender is used.
2. Surface Reconstruction:
o Converts the mesh into a continuous, smooth NURBS (Non-Uniform Rational
B-Spline) surface.
o Enables a more refined, editable model.
3. Parametric Modeling:
o Converts surfaces into feature-based CAD models using software like
SolidWorks, CATIA, NX, or Fusion 360.
o Allows modification and design improvements.
4. Exporting the Final CAD Model:
o The refined model is exported in IGES, STEP, or CAD-compatible formats.
o Ready for 3D printing, CNC machining, or further engineering analysis.

Applications of 3D Scanning and CAD Model Creation


Industrial Applications

1. Aerospace and Automotive: Used for reverse engineering, part validation, and structural
optimization.
2. Manufacturing: Quality control, rapid prototyping, and mold inspection.
3. Medical Industry: Prosthetics, orthopedic implants, and surgical planning.
4. Heritage Preservation: Digitizing historical artifacts and monuments for restoration.
5. Consumer Electronics: Designing ergonomic and aesthetic products.

Conclusion
3D scanning and reverse engineering provide precise, efficient, and cost-effective methods to
create digital replicas of real-world objects. By leveraging the right measuring devices and
systematic point cloud processing, industries can enhance product development, quality
control, and innovation.

With advancements in AI-driven automation, real-time scanning, and hybrid modeling, the
future of 3D scanning and CAD modeling promises even greater accuracy, speed, and
accessibility across various industries.
Case Study: Implementation of 3D Scanning
and CAD Model Creation in Industrial
Component Reproduction
1. Introduction
In modern manufacturing, the need for reverse engineering and component reproduction
arises when critical machine parts become obsolete. Traditional methods of manual measurement
and replication often lead to dimensional inaccuracy and increased lead time. This case study
explores how 3D scanning and CAD model creation were employed to replicate a discontinued
machine component with high precision and minimal time.

2. Problem Statement
Company: XYZ Manufacturing Ltd.

Issue: A crucial gearbox housing in a 15-year-old industrial press machine required


replacement due to wear and tear. However, the original design blueprints were unavailable, and
the OEM had discontinued production.

Challenges Faced:

 Lack of CAD Models or Technical Drawings


 Manual Measurement Inaccuracy (~±0.3mm tolerance)
 Longer Production Lead Time (~8 weeks)
 Potential Machine Downtime Leading to Losses (~$20,000/day)

Objective: Implement 3D scanning and CAD modeling to accurately reverse engineer the
gearbox housing for rapid and cost-effective reproduction.

3. Solution Approach
Step 1: 3D Scanning of the Existing Gearbox Housing

 Technology Used: Structured Light Scanner (ATOS Core 300, Accuracy: 0.02mm)
 Data Captured: Point Cloud (~2 million points)
 Processing Software: Geomagic Design X
 Time Taken: 4 hours
Outcome:

 A detailed point cloud model of the worn-out housing was generated.


 Alignment and registration of multiple scan angles were done to create a complete
model.

Step 2: CAD Model Creation from Point Cloud

 Software Used: Siemens NX


 Surface Reconstruction Method: NURBS-based surfacing
 Conversion to Parametric CAD Model: Feature extraction and solid modeling
 Time Taken: 6 hours

Outcome:

 A fully editable 3D CAD model was created.


 Dimensional verification ensured deviation of less than ±0.05mm from the original.

Step 3: Manufacturing the New Gearbox Housing

 Manufacturing Process: CNC Machining (5-Axis Milling)


 Material: Aluminum Alloy (6061-T6)
 Production Lead Time: 4 weeks (50% Reduction)
 Quality Control: CMM Inspection (Tolerance ±0.02mm)

Outcome:

 The new housing perfectly matched the original machine interface.


 Assembly and functionality tests were successful with no modifications required.

4. Results and Impact


Parameter Traditional Approach 3D Scanning Approach
Measurement Time 3-5 Days 4 Hours
Design Time 2 Weeks 6 Hours
Production Lead Time 8 Weeks 4 Weeks
Overall Cost $30,000 $18,000
Accuracy ±0.3mm ±0.05mm

Key Benefits:

✅ 50% reduction in production time ✅ 40% cost savings ✅ Increased accuracy by 6X ✅


Prevented losses of $20,000 per day in downtime
5. Conclusion
By integrating 3D scanning and CAD modeling, XYZ Manufacturing Ltd. successfully reverse-
engineered and reproduced an obsolete gearbox housing, saving time, cost, and potential
machine downtime. This case highlights the effectiveness of digital manufacturing
technologies in reducing reliance on OEMs and ensuring business continuity.

6. References & Sources


1. Geomagic Design X User Manual – Retrieved from www.3dsystems.com
2. Siemens NX CAD Modeling Guide – Retrieved from
www.plm.automation.siemens.com
3. ATOS Core 300 Datasheet – Retrieved from www.gom.com
4. Industry Case Studies on 3D Scanning Applications – Retrieved from
www.machinedesign.com

You might also like