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Exact Metrology Holds Open Houses at Both Its Locations

Product demonstrations and technical presentations from principals impress large crowds; 3D/CT scanners and NEW 3D printer line highlighted

On May 23, 2017, Exact Metrology held an open house at its facility in Cincinnati and the event was attended by over 100 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 Steve Young, 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.  Highlight of the event was the company’s new partner, EnvisionTEC, a builder of 3D printing equipment for myriad industries, for whom Exact was recently named Midwest dealer.  Also on display were a number of the other equipment lines represented by Exact, including Romer arms, GE CT scanning, Leica 3D imaging scanners and a variety of point cloud software advancements for the quality world.

Services on display at the Cincinnati 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.  Company representatives from the various equipment lines, as well as Exact Metrology’s team of application engineering and testing specialists, were present for demonstrations and technical presentations, throughout the event.

The EnvisionTEC line drew particular attention and Steve Young commented, “This new partner was a natural extension of our service work.  We do 3D scanning and were using a 3D printer, so we had that light bulb moment and decided to connect with a 3D printer builder to expand our equipment offerings.”   Exact represents EnvisionTEC throughout the Midwest.  EnvisionTEC is a Detroit-based builder of various 3D printers for the medical, dental, jewelry and various industrial sectors, offering machines to produce parts up to 18” cube.

As Steve Young further noted commented, “We constantly seek to find the optimum 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 or rent equipment or use our services to achieve the desired results on their metrology projects.”   Young credited his staff of metrology engineers, technicians and customer service personnel for their hard work, dedication and adaptability in seeking the correct solution to all customer challenges.

During the day, two big screen TV’s were raffled off to attendees, who also enjoyed a tasty pig roast luncheon.

Exact serves both industrial and commercial concerns, ranging from heavy equipment, automotive and appliance companies to nuclear test facilities and even museums, who routinely use metrology to examine artwork such as paintings and sculpture.

Cincinnati Photos:

Subsequently, on May 25, Exact held an open house at its Brookfield, Wisconsin (outside Milwaukee) location.

Attended by 70 companies in the area, the event was hosted by Exact Metrology co-president Dean Solberg in conjunction with Exact partners EnvisionTEC, Hexagon Metrology, PolyWorks, 3DSystems and ETI.

A variety of scanning equipment was demonstrated throughout two rooms in the facility. One highlight of the open house was the new Leica BLK360 Imaging Laser Scanner, a 360-degree scanner that allows high resolution scans for a full-dome in less than three minutes. Other devices showcased included the Hexagon Metrology Romer Absolute Arm, several Artec3D scanners, the Surphaser 100HSX, several Leica long range scanners and the ProCon CT scanner. While demonstration pieces were available to scan, attendees were able to bring in their own parts to show live 3D scanning on the screen.

Also present at the open house was Exact Metrology’s new 3D printer partner, EnvisionTEC, Inc. High-precision, high-detailed models illustrated the 3D printing capabilities of the Detroit-based manufacturer.

The Brookfield open house’s agenda consisted of four breakout sessions with experts in 3D metrology and scanning technology demonstrating their wealth of knowledge on the industry. The breakout sessions happened simultaneously during the day. During one presentation, Jason Reno of PolyWorks talked about what to expect in the industry for 2017. Another session was given by Dave Meyers, a Professor affiliated with Effective Training Inc. He instructed the audience on the use of GD&T Training (Geometric Dimensioning and Tolerancing). Greg George, Corey Mayeda and Mike Tsand from 3DSystems gave a discussion on 3DSystems Software: DesignX and Geomagic.

The guests enjoyed a full spread of delicious food for lunch and were given keepsakes such as mouse pads, pens, coffee mugs, and m&m’s, all with the Exact Metrology logo on them.

Wisconsin Photos:

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  • demonstrations
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Exact Metrology is an ISO 9001:2008 and AS9100 Certified Company and is also ITAR Registered.

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.  

For more information on this event or to arrange a demonstration, please contact:

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

 

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The machine line spans a range from desktop models to units capable of producing 10 cubic foot objects from fiber and thermoplastic materials

Exact Metrology Named Midwest Dealer for Envisiontec 3D Printers

Leading supplier of 3D printers partners with longtime supplier of metrology equipment

Effective immediately, Exact Metrology is now the greater Midwest dealer for EnvisionTEC, a Detroit-based manufacturer of 3D printers and materials.  

Exact Metrology is now the greater Midwest dealer for EnvisionTEC, a Detroit-based manufacturer of 3D printers and materialsEnvisionTEC supplies machinery and materials to a variety of industries, including automotive, aerospace, appliance, jewelry and life sciences.  The machine line spans a range from desktop models to units capable of producing 10 cubic foot objects from fiber and thermoplastic materials.  The company also produces a full line of materials, including more than 70 proprietary formulations for specific customer requirements. 

Exact Metrology offers a complete line of portable scanning and measurement technologies, as well as contract measurement for 2D and 3D laser scanning services, reverse engineering services, non-contact inspection, metrology services, 3D digitizing and training, long-range scanning plus its CT scanning services, usable by all types of manufacturing, packaging and product integrity concerns, as well as civil engineering, architects and municipal infrastructure developers.  

The machine line spans a range from desktop models to units capable of producing 10 cubic foot objects from fiber and thermoplastic materialsDean Solberg, co-president of Exact, notes, “The addition of EnvisionTEC brings our line to a new level of technology.  A natural extension of our services and equipment lines, especially in the areas of reverse engineering and product modeling, we were already using 3D printing in our own service departments, so it made perfect sense to extend our equipment lines into 3D printing and we were most impressed with the EnvisionTEC line and the company’s commitment to growth.  Exact is proud to be a part of that process.”   


For more information on this agreement, please contact:

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

Or

Steve Young
Exact Metrology, Inc.
11575 Goldcoast Drive
Cincinnati, OH 45249
Local: 513-831-6620
Toll Free: 866-722-2600
www.exactmetrology.com
stevey@exactmetrology.com

Exact Metrology is an ISO 9001:2008, AS9100 Certified and ITAR Registered  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 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.

  • 3D laser scanning
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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.

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Project Puts Exact Metrology On The 3D Map With Fermilab

High precision 3D mapping supports installation of a new beam transport line for scientific research

Fermi National Accelerator Laboratory (Fermilab), America’s premier high-energy particle accelerator laboratory, in Batavia, Illinois, collaborates with scientists from around the world to perform pioneering research, operate world-leading particle accelerators, plus experiment and develop technologies for science supporting U.S. industry.

In 2014, Fermilab contracted Exact Metrology to work on a project known by its location as “Main Injector Ring Section MI-10.” Horst Friedsam, Head of the Alignment & Metrology Department at Fermilab, led the week-long project with Exact Metrology, which involved 3D mapping of existing equipment in order to yield data to support the placement and installation of an additional beam transport line.

Exact Metrology performed the scanning in section 10 of the Main Injector Accelerator, which is situated in a tunnel about 10 m below ground with a circumference of approximately two miles. The Main Injector accelerates a proton particle beam, arriving from the 8 GeV (Giga-electron-Volts) Booster, to 120 GeV and subsequently blasts it into a stationary target to generate the world’s highest intensity neutrino beams.

Recently, Fermilab has been working on a new Deep Underground Neutrino Project (DUNE) to provide a neutrino beam to the Homestake Mine in South Dakota. This project features access to research facilities 2 miles below ground, which is ideal for neutrino experiments requiring shielding from cosmic ray events. In order to deliver a neutrino beam to the DUNE, a new beam transport line that fits within the existing beam line infrastructure was required. As a result, data scanning, full CAD modeling and photo overlays of a large section of the currently installed Main Injector equipment was needed. The collected data were crucial for the design of new beam elements and visualizing interferences with existing components.

3D Map will help Fermilab install a new beam transport line | Exact Metrology

3D Map will help Fermilab install a new beam transport line

The Alignment & Metrology Department maintained a high precision control network throughout the laboratory complex. For the scanning process, a Leica ScanStation P20 ultra-high speed 3D Scanner was used in conjunction with special laser scanner targets, modified to fit within the existing control network points. Exact Metrology’s Leica ScanStation P20 was chosen for its combination of high accuracy and low scan noise, plus its industry-leading environmental specifications for industrial as-built documentation. The software chosen to aid the process was Leica Cyclone, producing TruView—a web-enabled panoramic point viewer allowing the user to view, pan, zoom, measure and mark up point cloud data over the web. Additionally, RSL300 laser scanner target markers from Berntsen International Inc. were mounted concentric to 1.5” radius steel half spheres interfacing with Exact Metrology’s laser tracker nests. The coordinates of the control network, determined at the millimeter level, were provided to Exact Metrology to globally register all scans relative to Fermilab’s system. Thus, the end product provides information for all scanned objects in the common coordinate system used for the entire Fermilab site.

Fermilab has a long-existing relationship with Exact Metrology, having purchased and rented equipment from their instrument pool plus contracted for metrology services as on-site work, such as this scan.

Exact Metrology is an ISO 9001:2008 Certified Company.

ExactMetrologyLOGOExact 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.

For more information on this new system, please contact:

EXACT METROLOGY, INC.
11575 Goldcoast Drive
Cincinnati, Ohio 45249
Phone: 513-831-6620
Toll Free: 866-722-2600
www.exactmetrology.com
stevey@exactmetrology.com
Steve Young, President

Or

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

Or

FERMI NATIONAL ACCELERATOR LABORATORY (FERMILAB)
1117 N Washington Ave
Batavia, IL 60510
Phone: 630-840-2787
Horst Friedsam

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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MJC Builds Multi-Axis Rotary Forging Machine for Advanced Research in Aerospace… 90 Percent Material Savings Possible

See the MJC video HERE.

Custom machine tool builder in California contracts with research center at university in Glasgow, Scotland to design specialized equipment for forming new jet engine structures; machine completely controlled by Siemens CNC  

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AFRC facility performs fundamental and applied research on the forming and forging of metals, primarily for aerospace applications. A full battery of materials and performance testing is conducted at AFRC by a team of materials and process experts

MJC Engineering is a custom machine tool builder, specializing in metalforming machines for such applications as spinning, flow forming, wheel spinning and rotary forging.  The company was recently contracted by the Advanced Forming Research Centre (AFRC) at the University of Strathclyde in Glasgow, Scotland for a very unique application, namely, a cold-forming rotary forge press that works the material between two synchronized rotary dies.  The dies operate in angle from the parallel.  Typically, the angle is fixed but, on this custom designed machine from MJC, the angle is fully programmable.  This configuration allows compression in a concentrated area and provides a more efficient method for metal deformation, while producing superior mechanical properties in the finished section.  Up to 90 percent material savings can be achieved by the use of this revolutionary metalforming technology, in comparison to conventional machining from a solid blank.

Operator loads workpiece during test run-up on machine; very hard aerospace materials such as Hastelloy and Inconel are typically processed

Operator loads workpiece during test run-up on machine; very hard aerospace materials such as Hastelloy and Inconel are typically processed

The aim of this new CNC technology, according to MJC company president Carl Lorentzen, is to make the aerospace engineers rethink how they design their products, so that a maximum material savings on exotic and costly metals can be realized.

Rotary forging can be defined as a two-die forging process that deforms only a small portion of the workpiece at a time, in a continuous manner.  The reduced instantaneous area of tool and workpiece contact means lower forging forces are required to cause deformation in the material.  Typical components for rotary forge operations are round or cylindrical hollow parts that deploy expensive or exotic alloys, require extreme material property targets or involve very complex geometries.  At AFRC, the rotary forging machine provided by MJC is processing AerMet® 100, Inconel 718 and Allvac® 718Plus®, Ti-6Al-4V as well as the creep-resistant Ti6242 and some beta alloys.

New rotary forge press from MJC, built specially for the Advanced Forming Research Centre (AFRC) at the University of Strathclyde in Scotland. Two independent and synchronized rotary dies are fully programmable on the Siemens CNC to affect 0-45º pitch angles

New rotary forge press from MJC, built specially for the Advanced Forming Research Centre (AFRC) at the University of Strathclyde in Scotland. Two independent and synchronized rotary dies are fully programmable on the Siemens CNC to affect 0-45º pitch angles

Onboard the machine, the bottom and top spindles pivot from 0-45º, operated by AC vector motors and drives, plus an overall motion control CNC, all provided by longtime supplier to the builder, Siemens.  The CNC is a Sinumerik 840D, which controls all the axis and spindle motion, hydro and servo positioning valves, plus the synchronization of up to four cylinders for the integrated motion of the rotary dies.  In the processing of the workpiece, the control is monitoring all machine conditions, while maintaining the synchronized angles of the twin rotary dies.

Siemens CNC controls the entire machine process

Siemens CNC controls the entire machine process

Programmed motion sequences on the machine must be maintained with high precision to avoid improper deformation of the materials during the cold-forming process.  In a manufacturing environment, where the high production output of parts is critical, this process must remain extremely well-regulated, documented and monitored.  The CNC has the capability to upload all data in real time.

The unique operation of this MJC rotary forging press involves the application of pressure on a small portion of material at a time, reducing stress and saving up to 90% in material, compared to subtractive machining from a solid blank

The unique operation of this MJC rotary forging press involves the application of pressure on a small portion of material at a time, reducing stress and saving up to 90% in material, compared to subtractive machining from a solid blank

Carl Lorentzen comments further on this MJC development, “Though the concept of the rotary die forge is certainly not new, the computer-controlled synchronized dual rotary dies on this machine offer a number of unique advantages in the cold-forming process of metals.  The idea originated in a somewhat different form in the automotive market with the development of a front wheel hub hollow shaft.  The cold-forming of metal around a bearing was combined with robot loading in production.  The concept, combined with the Siemens CNC and its ability to control all the motion so precisely, made the development of this machine more practical for us.”

MJC is a custom machine tool builder, with equipment currently serving in the military, aerospace, general metalforming and automotive after-market segments of industry.   The company is a member of PMA, NFTC and AMT.

The AFRC is jointly sponsored by the Scottish government, Scottish Enterprise and a variety of international aerospace manufacturers and engineering firms, including Boeing, Rolls Royce, TIMET, Aubert & Duval and Barnes Aerospace.  It has operated as a world-class facility, supporting fundamental and applied research into the forming and forging of metals, since 2009.  Having doubled in size recently, AFRC is expanding its market applications into the automotive, energy and marine markets.  The center can currently heat, shape, finish, measure, test and analyze all types of metal materials and components in-house.  The research done here comprises investigations into residual stress, die life, process characterization, materials characterization, heating and thermal processes, super-plastic forming, sheet forming and related technologies in automation, metallurgy and metrology.

The key challenge for AFRC, according to its website, is to take low maturity technology developed in a university environment and successfully deploy it into a manufacturing facility.

See the video of MJC @FabTech HERE.

For more information on this story, please contact:

MJC ENGINEERING & TECHNOLOGY, INC.
15701 Container Lane
Huntington Beach, CA 92649
Phone: 714-890-0618
Fax: 714-895-3561
Web: www.mjcengineering.com
Email: clorentzen@mjcengineering.com or carlson@mjcengineering.com
Attention: Carl Lorentzen, President or Per Carlson, VP

or

SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarcom.industry@siemens.com
Attention: John Meyer, Manager of Marketing Communications

Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.

Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.

The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.

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