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Tag Archives: 3D scanning

Exact Metrology Offers Tips on Airfoil Scanning Procedures

 Market Leader in 3D and CT Scanning Details a Typical Airfoil Procedure

Exact Metrology, a leading supplier of 3D laser and CT scanning equipment and services details the steps to a successful airfoil evaluation.  

Exact Metrology AirfoilSCAN PROCESS:

The scan can occur at the customer’s facility or at Exact Metrology’s. In many cases, it is most cost effective for the digitizing or scanning to take place at the Exact facility. However, in certain instances, when turnaround time is of great importance or downtime of the scanned component is critical, the scanner is mobile and available for onsite operation.

The airfoils that are typically provided by customers will be received by Exact Metrology for full documentation with photos, measurements and any surface markings or serial numbers recorded prior to any high definition scanning.

Setup

The mobility of the Exact scanner allows a high degree of flexibility in performing onsite scans (Option A) at a customer facility or the more cost efficient in-house scan at the Exact facility (Option B).

Due to the reflective nature of the blades, a thin coating of Magnaflux spray is applied. The SKD-S2 spray is a second phase of the crack checking processes. Phase 1 is a die penetrant that will not be used typically. The spray meets the requirements for AMS 2664, ASTM E165 and is ASME approved. (Health – 1, Flammability – 4, Reactivity -0, No Specific Hazard). See MSDS 0166 for more information on the SKD-S2 product.

When scanning the blade, Exact uses a fixture device. Targets will also be used to constrain data during the alignment phase. Targets will be placed using magnets on either side of the air foil. The fixture itself will also act as an alignment constraint while holding the airfoil in place and allowing Exact technicians to capture maximum data on the part without moving or touching the part. A manual or automatic turntable may be used to allow enhanced scanning and registration access to the part.

Scanning

The part is positioned on the rotating table or on a stationary marble top and scanned from multiple perspectives. This procedure is repeated multiple times to provide complete coverage of the part. Known geometric objects, cubes and spheres are often placed in the scene for quality assurance and validation during the validation stage.

The scanner used on these projects is a Breuckmann Stereo 3D Scanning system. This device uses a unique halogen structured white light projection system with dual 6.6 mega-pixel cameras. The scanner is the highest resolution scanner available on the market and was specially built for Exact Metrology in Germany.

Registration

The registration process can be done with or without targets. Both registration methods have different techniques with similar results. Essentially, the targeting procedure uses an automated fitting of point clouds or scan worlds together, based upon three common positions on the part or scene. This process has been simplified with modern software technology. The software will then analyze every point with overlap and run a best fit algorithm over hundreds of iterations to find the tightest and best alignment. The result of this process will yield a fully registered and organized point cloud.

Validation

It is important to verify the automated method with targeting and adding known geometric shapes to the scan. All scans are documented with notes, computer logging and digital photos accompanying the recorded scan setup within the software. A CD copy of all digital data is recorded prior to returning the part or teardown.

MODELING PROCESS:

Once the data is gathered and the registration process is complete, the point cloud or data set can now be worked. The first step is to triangulate or mesh the points together. As part of this early process, points are “intelligently” removed from the network by algorithms in the software. Essentially, the points of redundancy and overlap are decimated and averaged. This mesh is further manipulated by reducing the triangles and points along flatter areas and retaining more triangles in areas of curvature and complexity. This poly mesh can now be exported as a complete *.STL file or similar format.

Surfacing

The process of fitting NURBs and geometry to the poly mesh or point cloud can be a time-consuming and arduous process. A surface is basically draped over the mesh and smoothed to be reflective of the actual part. Once this task is completed and a complete watertight object is created, the model is ready to be exported to nearly any format via various methods. The end file format is entirely up to the client and the limitations of existing conversion tools available today.  A final 3D solid model can be provided as a “dumb solid” with no parametry or history tree as an imported object. The available formats include: Siemens NX, Pro/E Wildfire, AutoCAD, AutoCAD Inventor, SolidWorks, as well as generic formats such as IGES, STEP, ParaSolid (X_T) and others.

Parametric Modeling

The final deliverable is a parametric model. Unlike a solid model, the parametric model possesses relationships of all dimensions within the CAD. With these relationships, the CAD model can be manipulated and fine-tuned without disturbing the overall geometry of the part. For this workpiece, the specific parameters of each cross section within the model can be independently modified without disturbing neighboring cross sections. The end result is a Pro/Engineer CAD model with known geometry that is fully adjustable and possesses a design history.

 

For more information on this application, please contact:

Dean Solberg
Exact Metrology, Inc.
20515 Industry Avenue
Brookfield, WI 53045
Phone: 262-533-0800
Local: 866-722-2600
www.exactmetrology.com
deans@exactmetrology.com

Exact Metrology is an ISO 9001:2008 and AS9100 Certified Company.

Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D and CT scanning, reverse engineering, quality inspection, product development and 2D drawings.   The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.  

Exact Metrology offers a complete line of portable scanning and measurement technologies as well as contract measurement for 3D laser scanning services, reverse engineering services, non-contact inspection, metrology services, and 3D digitizing. The company’s newest equipment includes a CT Scanner, the first in America being used for metrology rather than medical testing. Exact sells and rents metrology equipment solutions, in addition to providing testing as a service and application software training.

 

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Exact Metrology Receives Official Certification for AS9100

Exact Metrology proudly announces it has received official AS9100 certification. The Aerospace Standard 9100 includes the requirements for aviation, space and defense organizations.  This certification evidences Exact Metrology practices a Quality Management System (QMS) that consistently meets customer expectations.  Exact Metrology management has been heavily involved with the QMS process. This starts with the setting of Quality Policy, Quality Goals and Objectives. Management Review looks at the data from QMS, sees that Quality Goals are met, sets new ones and strives for continuous improvement. The advantage of this stringent Management Review is that it provides a basis for reviewing goals and performance against goals that are periodically reviewed. As a result, according to company co-founder Dean Solberg, customer satisfaction has increased because, “…the Goals and Objectives of the QMS take the customer’s needs into account and the Exact team can react and plan accordingly.”

Benefits of implementing AS9100 include well defined and documented procedures to improve the consistency of output, quality is constantly measured, procedures ensure corrective action is taken whenever defects occur, reducied overall cost, appreciably lower defect rates and earlier detection, exposure to new markets and retention/increase of market share in existing sectors, internal operational efficiency and overall better process control and workflow.

The company is also ISO9001:2008 certified. This is the only ISO standard that requires certification and is an internationally recognized Quality Management System that governs the sale and service of 3D non-contact and contact measuring equipment for inspection and reverse engineering in the commercial, aerospace, medical, automotive and industrial sectors. The ISO9001:2008 certification highlights the commitment, dedication and service Exact Metrology employs for customers.

Exact is also certified by ITAR, the International Traffic Arms Regulation. As a result, Exact Metrology has a competitive advantage when attracting and retaining defense business. Prime contractors are obligated to comply with ITAR requirements and these same requirements must be employed by subcontractors. Subcontractors such as Exact Metrology, who demonstrate compliance with ITAR standards, are clearly more desirable resources for prime contractors. Finally, being ITAR certified gives Exact Metrology the opportunity to do business with defense companies overseas, a growing market for the company currently.

Exact Metrology also has a Federal Firearms License, giving them the ability to send and receive weapons for quality control and inspection.

For more information on these developments, please contact:

Dean Solberg
Exact Metrology, Inc.
20515 Industry Avenue Brookfield, WI 53045
Phone: 262-533-0800
Local: 866-722-2600
www.exactmetrology.com
deans@exactmetrology.com

Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D and CT scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.  

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Exact Metrology Purchases CMM For Its Cincinnati Location

Exact Metrology has purchased a Brown & Sharpe CMM for its Cincinnati operation, according to company co-president Steve Young. A fully featured coordinate measuring machine, this CMM is a Global Excel 1222-10. It has a measuring volume of 48” on the x-axis, 88” on the y-axis and 40” on the z- axis. The machine also includes PC-DMIS CAD ++ and PolyWorks software. Additionally, the Global Excel 1222-10 has a motorized probe head with a laser scanner attachment.

This is the first conventional arm that Exact Metrology has purchased and it is equipped with laser scanning capabilities. Like all coordinate measuring machines, it only needs to be programmed to run. Additionally, the Brown & Sharpe CMM can simultaneously work on multiple parts, providing high accuracy and work protocol efficiency.

In use, the CMM will augment the full battery of 3D laser and CT scanning equipment, plus 3D printers, now onsite at the Cincinnati facility of Exact Metrology. Exact also operates a sister location in Brookfield, Wisconsin, near Milwaukee.

The new CMM will be installed in December.

For more information, please contact:

EXACT METROLOGY, INC.
Steve Young or Amy Cupp
11575 Goldcoast Drive Cincinnati, OH 45249
Phone: 513-831-6620
www.exactmetrology.com
info@exactmetrology.com

Exact Metrology is an ISO 9001:2008, AS 9001: 2008 and ITAR Certified Company.

Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements. 

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Exact Metrology Helps Local Artist Produce Statues for Great American Ballpark

Cincinnati artist Tom Tsuchiya combines his talents with 3D laser scanning from market leader

small_0007_tony-perez-rst-1Cincinnati, Ohio is home to a rich baseball tradition and one young sculptor has combined his creativity with a new, high-performance image scanning technology to create statues for Great American Ballpark, home to the Cincinnati Reds.

In preparing the statues, artist Tom Tsuchiya starts with an approximately 18” high ceramic model. He then supplies the model to the technicians at Exact Metrology’s Cincinnati facility.  Exact is a leading supplier of 3D and CT imaging equipment. They also perform scanning services for numerous manufacturing industries, as well as a diverse assortment of civil engineering, fine arts, commercial and other concerns.  Their subject projects recently included the Fermi Lab particle accelerator, the lions in front of the Chicago Art Institute, a construction site for materials consumption projection, a cross at Our Savior’s Lutheran Church in Hartland, Wisconsin, existing buildings for wiring and ductwork refurbishing, a painting for possible forgery, old sculptures for structural integrity and an actual crime scene for use in the investigation and courtroom proceedings.

smallpeteroseIn this baseball scenario, the scan of the model is prepared as a high-density electronic file with over a million points of information per second captured on the geometry of the proposed statue.  This file is then posted in the cloud and downloaded by a local foundry. The foundry takes the point data and prepares a mold for the statues, which often measure up to 8’ in height.  The brass is poured to produce a statue, then meticulously sculpted by Tom Tsuchiya into his final creation.  As the photos here attest, the statues and plaques made for Reds Hall of Famers Tony Perez, Johnny Bench and others evoked some strong emotions and memories.

Co-Presidents at Exact, Steve Young and Dean Solberg, are big sports fans, so this project was truly a labor of love.  As Young, supervisor of the Cincinnati facility, explains, “We didn’t see a dry eye at the celebration for Tony Perez, a true gentleman and one of the brightest stars in a very crowded sky, that day.”   Joining Perez for this momentous occasion were fellow teammates Johnny Bench, Pete Rose, Joe Morgan and other members from the famous “Big Red Machine” of the 1970’s.

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For more information on this story and all Exact services and equipment offerings, please contact:

Steve Young or Amy Cupp
Exact Metrology, Inc.
11575 Goldcoast Drive
Cincinnati, OH 45249
Local: 513.831.6620
Toll Free: 866.722.2600
www.exactmetrology.com
info@exactmetrology.com

Exact Metrology is an ISO 9001:2008, AS 9001: 2008 and ITAR Certified Company.

Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements. 

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Exact Metrology Holds Open House in Brookfield, Wisconsin

3D scanners from Exact Metrology engineering specialistsProduct demonstrations and technical presentations on 3D printing & CT scanning engage a large audience

On June 23, 2016, Exact Metrology held an open house at their Brookfield, Wisconsin location, showcasing its newest products in 3D printing and CT scanning equipment. The event was attended by a large number of people from several Midwestern states and a diverse range of business sectors, including manufacturing companies, civil engineering firms, municipalities, local artists and art museums.

Hosted by Dean Solberg, Exact Metrology co-president, the day included product demonstrations featuring the newest technology in 3D & CT scanners from Exact Metrology engineering specialists. Ten stations were set up throughout the facility, each demonstrating equipment from the top names in the industry and most of the equipment was available for hands-on use by the attendees. Products included the Romer measurement and scanning arm, Hexagon Q Flash, Leica tracker, Surphasers, ATOS II Blue Light Scanner, Artec Space Spider and Exact Metrology’s newest acquisition, the ProCon Compact CT scanner. Several attendees brought their own parts and had them scanned onsite, then 3D printed.

Running simultaneously throughout the day were several breakout sessions on: 3D systems (Geomagic Design X/Geomagic for Solidwork) presented by Mike Tsang; 3D Software Innovmetric (Polyworks) by Julien Thibodeau Gagne; and 3D printing by Mastergraphics demonstrated by Kevin Carr.

ProCon CT scannerAn especially impressive product demonstration included scanning a single grain of salt with the ProCon CT scanner. The scan picked up details as minute as the ridges in the salt grain, illustrating the scanner’s ability to capture the most precise details inside and out. CT scanning currently used by Exact technicians to examine injection molded parts, castings and forgings, evaluating porosity, grain structure, filament distribution etc. Data can be instantly compared to CAD files in the point cloud for assessment.

­­­­These high-definition CT imaging devices were, until recently, only available for use in the medical field. They now serve a wide range of product applications, including but not limited to, industrial, manufacturing & construction, power generation/nuclear, medical, aerospace and the arts, the latter already seeing applications in the detection of forgeries and sculpture structural integrity, as examples.

Exact Metrology offers a complete line of portable scanning and measurement technologies as well as contract measurement for 3D laser scanning services, reverse engineering services, non-contact inspection, metrology services and 3D digitizing. The company’s newest equipment includes a GE CT Scanner at its Cincinnati location, the first in America being used for industrial metrology rather than medical testing. Exact sells and rents metrology equipment solutions, in addition to providing testing as a service and application software training.

  • 3D laser scanning services
  • Exact Metrology offers a complete line of portable scanning

For more information on this event, please contact:

Dean Solberg
Exact Metrology, Inc.
20515 Industry Avenue
Brookfield, WI 53045
Phone: 262-533-0800
Local: 866-722-2600
www.exactmetrology.com
deans@exactmetrology.com

Exact Metrology is an ISO 9001:2008 Certified Company.

Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D and CT scanning, reverse engineering, quality inspection, product development and 2D drawings.   The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.  

 

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Take A Look Inside! Exact Metrology Opens Its Doors

Product demonstrations and technical presentations from principals impress large crowd

On May 14, 2015, Exact Metrology held an open house at its Brookfield, Wisconsin facility and the event was attended by over 125 local area companies, comprising quality assessment, design engineering and management personnel from many of the leading manufacturers in the region. Hosted by company co-president Dean Solberg, the day included ongoing product demonstrations of the various metrology equipment brands offered for sale, lease and rental by Exact, as well as the testing procedures provided as a service by this unique metrology supplier.

Exact Metrology | Open House

Services on display at the Brookfield open house included 3D scanning, reverse engineering, quality inspection, instant scan-to-CAD comparison and a full suite of PolyWorks software solutions. Equipment shown at the event included Aicon 3D systems, Breuckmann 3D scanners, Leica Geosystems, Romer and Hexagon brands of scanning devices and related hardware, all of which were available for hands-on use by event attendees.

A new product of great interest to attendees was the Breuckmann steroScan, a flexible scanning system for precise 3D digitization and metrology. Applications for this product include quality inspection, reverse engineering, rapid prototyping, deformation analysis and digital documentation. Because of the adjustable focal length of the scanner, products from small components up to large sections of automotive and aircraft parts can be scanned with high resolution and accuracy. Breuckmann is a company of Aicon 3D Systems.

During the event, technical presentations were made by Aicon, PolyWorks by InnovMetric and Exact personnel on the newest advancements in 3D scanning technologies. The presentations were given to a “full house” of interested attendees.

As Dean Solberg commented, “We seek to find the right combination of equipment and services to suit the applications and challenges presented by our customers. In some cases, it’s a matter of matching the right standard equipment to the job, while at other times we bring custom solutions and services to our customers, whether they buy, lease, rent or simply use our services to achieve the desired results on projects.” Solberg credited his staff of metrology engineers, technicians and customer service personnel for their hard work, dedication and adaptability in seeking their correct solution to all customer challenges.

Exact Metrology is an ISO 9001:2008 Certified Company.

For more information on this new system, please contact:

EXACT METROLOGY, INC.
Dean Solberg
20515 Industry Avenue
Brookfield, WI 53045
Phone: 262-533-0800
Local: 866-722-2600
www.exactmetrology.com
deans@exactmetrology.com

Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.

Continue reading