Looking for a new way to improve your daily workflow of automotive customization? See how Scantech’s cutting-edge 3D scanning solutions can improve the automotive film paint design in this cast study.
The client is a leading company in the industrial design and 3D printing sectors in China, with a strong presence in the automotive film industry. Their software SmartCut is widely used in the automotive film sector.
The software features a comprehensive database of vehicle models and offers tailored film cutting solutions for each, covering a large proportion of vehicles on the market.
For vehicles not included in the database, the company uses Scantech’s advanced 3D scanning solution to quickly and accurately capture the geometry of the vehicle, providing cutting-edge solutions for automotive film applications.
Challenge of Measuring Large Vehicles
The client’s main challenge was to develop an efficient and precise method for scanning the entire vehicle, including both the exterior and intricate interior areas that required film application.
Once the vehicle’s 3D model was accurately captured, the next step was to process the data using their proprietary software to generate cutting patterns for the film.
The key goal was to ensure that the patterns fit the vehicle contours seamlessly, extending up to the edges with minimal seams.
The client sought a solution that not only offered precision but also reduced the need for manual adjustments, enabling a perfect fit for the film application, ensuring both aesthetic quality and durability.
Scanning Challenges
Several key challenges were encountered during the scanning process:
Large -Size Measurement
The vehicle’s large size made it challenging to complete the scanning in one go. For 3D scanners with small measurement volume, it is time-consuming to scan the entire car. The 3D scanner had to be repositioned multiple times to capture all angles and surfaces effectively.
Limited Interior Spaces
Tight spaces can be difficult to reach with a 3D scanner. There is limited room to maneuver the 3D scanner or adjust its position to capture all angles. Besides, some interior elements can obstruct the 3D scanners’ view.
Reflective Surfaces
Many of the vehicle’s surfaces, such as the body paint, were highly reflective, which posed a challenge for the scanning equipment to capture accurate data.
Solution Implemented
To address these challenges, the following solution was implemented:
TrackScan + SIMSCAN
TrackScan is a state-of-the-art optical 3D scanner, ideal for measuring large and complex objects like vehicles. Its large-volume measurement and high measurement rate ensures efficient 3D scanning. The system offers non-target 3D scanning, making it highly versatile for automotive applications.
Thanks to its compact size and robust performance, SIMSCAN 3D laser scanner is excellent for measuring narrow spaces. Its accuracy is up to 0.020 mm, which ensures every details is captured precisely.
Scanning Process
The scanning process was performed using TrackScan and SIMSCAN. TrackScan was used to capture the vehicle’s exteriors, ensuring all surface details and 3D data were fully captured.
For the interior, SIMSCAN was utilized to reach even narrow and deep areas, providing comprehensive 3D scans of the entire space. The entire vehicle was scanned in approximately 3 hours.
Solution Advantages
The solution provided several distinct advantages:
Efficient Large-Scale Scanning
The size of the vehicle was not an issue, as the TrackScan provided precise 3D scanning over large areas. With a measurement rate of up to 2.6 million measurements per second, the scanning process was both fast and efficient.
Easy Measurement
The optical 3D scanner comes with software TViewer which features dynamic tracking and super repositioning. Its dynamic tracking allows measurement in vibration environments such as factories and workshops.
And its super positioning ensures the precise measurement of large-scale parts. Therefore, the engineer can move the 3D scanner freely and making the measurement easy.
Handling Reflective Surfaces
TrackScan’s advanced blue laser scanning easily overcame the challenge of reflective surfaces.
Unlike conventional scanners that require special adjustments or surface treatments for shiny or reflective surfaces, the TrackScan + SIMSCAN was able to scan the vehicle’s exterior without the need for any additional preparations, ensuring high-quality data capture.
Access to Narrow Interior Spaces
For interior scanning, where space is limited, the SIMSCAN 3D scanner’s short camera distance and deep-hole scanning mode enabled the system to reach areas that larger handheld scanners would typically miss.
This functionality allowed for complete data capture even in confined spaces such as door edges and under-carriage sections.
Virtual Film Application
For vehicle models without pre-existing cutting data, the 3D scan data was processed using the client’s software to create a virtual film application. This approach ensured precise film cutting, minimized material waste, and reduced costs by tailoring the film to fit each vehicle model’s exact shape and size.
Conclusion
By integrating advanced 3D scanning technology with their software platform, the client was able to overcome significant challenges in the automotive film application process. The use of the TrackScan + SIMSCAN scanner allowed for quick, accurate, and efficient capturing of vehicle data, even in difficult-to-reach and reflective areas.
The software’s virtual film application feature further optimized material usage, reducing waste and ensuring a perfect fit for every vehicle.
This solution has provided a competitive edge in the automotive film industry, empowering the client to serve more customers while maintaining the highest standards of quality, efficiency, and cost-effectiveness.
