It may come as a surprise to people living in the digital age to find that there are many things in the world without a digital blueprint or CAD history, yet this is a problem that frequently arises in the field of product design. In this case, reverse engineering—a famously time-consuming process—is used by part manufacturers. Innovative manufacturers, however, use 3D scanning technology to substantially speed up the workflow of these projects while simultaneously maintaining accuracy and the quality of the finished item. These manufacturers are tasked with making or fabricating new parts without an attached digital file.
More industries are starting to adopt 3D scanning as it becomes more commonplace, including product development and reverse engineering. A projection from MarketsandMarkets projects that the overall market for 3D metrology will increase from $10.6 billion in 2022 to $15.9 billion by 2027, with applications in reverse engineering serving as one of the key drivers.
Due to the capacity to quickly and precisely scan measurements, features, and details during numerous design iterations, as compared to traditional measurement methods, more customers are using 3D scanning for reverse engineering projects. When faced with the need to produce customised and spare parts, parts for which production has been discontinued, or parts without an associated CAD file, automotive, aerospace, defence, and other part manufacturers have started using 3D metrology to quickly and precisely reverse engineer existing objects.
The information provided by 3D scanning not only shortens the feedback loop between the design, prototyping, and testing phases in reverse engineering projects but also offers recommendations for the viability of subsequent manufacturing steps and guarantees that the produced part will adhere to the original design intent.
3D Scanners Provide More Detail in Reverse Engineering Applications
A physical object’s height, width, depth, diameter, and circumference must be measured, as well as additional geometries like the object’s shape, which may have non-linear edges and angles. Also, it can be important to record intricate information like the radius of specific features or qualities that could exist beneath or between other features.
While conventional measurement methods like callipers and coordinate measurement machines (CMM) can measure a part’s basic physical dimensions, 3D scanning accurately and efficiently gathers all the data related to the entire part, giving designers a better understanding of the part in its entirety, including its surfaces, details, and intricate features. Designers are forced to make assumptions about the more difficult-to-obtain aspects of the item without the benefit of extensive 3D scanning, and these assumptions frequently result in a poorly designed product that is not exactly what the consumer needs. The thoroughness of the data that 3D scanning provides offers significant benefits to the overall application and workflow.
The 3D measuring procedure typically consists of several steps: A point cloud is first formed by scanning the object and identifying its shapes, contours, and measurements. The gathered data is then transformed into a CAD file or a 3D model of the component. The part can then be modelled using software to create a “blueprint” that is utilised to process the part.
Many 3D scanning methods are available to complete the first step of data collection. Nonetheless, arm-mounted laser scanners are often more advanced when it comes to capturing smooth, organic geometries up to a certain level of detail and have fewer limits than other technologies. The use of a hard probe, which records exact geometrical details as well as sharp machined lines, can increase precision. Several sophistication levels of 3D scanners can measure items ranging in size from a few millimetres in diameter to as large as a boat hull.
Product designers can start the process of reverse engineering to build new components or replace parts using these 3D scanning technologies. For instance, in the automotive industry, a touch probe could be used to collect data on the machined elements of a vehicle door whereas a laser scanner could be used to scan a car door and capture the more organic, moulded portions of the door. The gathered information might subsequently be used to produce CAD files and models for goods like replacement parts for an automobile that might be no longer in production.
The same technology can be used to reverse engineer replacement parts for which a CAD file already exists, however, this method ignores the possibility that the part has already been used or worn down over time. When this happens, 3D scanning not only expedites the design process but also guarantees that replacement parts are more effective from a usage standpoint because they are built based on the actual, real-world state of a certain part or machine.
The Benefits of Reverse Engineering with 3D Scanning
Time is of the essence in design-related applications because the product development process is frequently drawn out, expensive, and involves numerous iterations. According to estimations, the technology can speed up the development process of data analysis and design validation by up to 80% when compared to conventional approaches, making it possible to reliably and effectively reverse engineer an existing product.
Also, once the prototype is constructed, the user will be aware of the part or product’s ability to be manufactured and can decide early on in the design phase if it is doable. Moreover, 3D scanners can be utilised once the prototype has been constructed to determine whether the part adheres to the design intent. In other words, even if it could be produced, would it function properly, fit where it should, and respond to pressure and wear the way it ought to? Due to the likelihood of several revisions during reverse engineering projects, the ability to identify such problems early in the process by utilising accurate and effective 3D scanning enables users to significantly shorten the development phase. Also, a high-quality component or product that will function as intended can be introduced to the market more quickly with a shorter feedback loop.
Additional advantages include the ability to produce higher-quality finished parts and products because 3D scanning ensures a thorough understanding of the part and all its complexities, as well as the reduction of scrap and waste associated with having fewer unusable design iterations and the elimination of finished parts that do not match the design intent.
3D Metrology Keeps Pratt Miller Ahead of the Pack
An engineering and product development firm with origins in motorsports, Pratt Miller, has won numerous races and championships in competitions like Corvette Racing. Ferrari, Porsche, BMW, Aston Martin, and Lotus are just a few of the formidable opponents the corporation has faced and prevailed over. With eight victories in the 24 Hours of Le Mans, Corvette Racing has proven that they are a team that comprehends the value of speed and accuracy as well as the significance of meticulous inspection and data analysis before, during, and following a race.
The team relies on data accuracy, measurement arm portability, and ease of setup from FARO® ScanArms throughout their procedure to gather data that keeps them on track during the 24 Hours of Le Mans. Corvette Racing and Pratt Miller most recently deployed FARO technologies to return to the track with the Corvette C8.R in search of yet another victory at Le Mans, even though the team has worked with FARO for four generations of race cars.
Precision and execution are crucial in racing. According to Frank Wilson, quality manager at Pratt Miller, “Winning starts with preparation before the car even hits the racecourse and having the necessary tools and processes for our team to be successful. “For more than 20 years, Pratt Miller has designed, built, and raced the cars for Corvette Racing, and our team is eager to return to the 24 Hours of Le Mans in search of our ninth victory.”
To produce four generations of Corvette race vehicles, Wilson explains, “We have relied on FARO Technology to scan better, scan faster, and scan more. And we’ve just finished doing it for the Corvette C8.R, which will race at Le Mans for the first time this year.
Pratt Miller uses a range of FARO ScanArms in their operations. In the fast-paced world of professional motorsports, the accuracy, portability, and capacity to collect and gather data quickly are important. “The FARO metrology solutions are used from the earliest stages of our aero development, in reverse engineering, to support the design and inspect fixturing and moulds before we start manufacturing, as well as in process at final inspections of race car components and for correlation of test data to on-track results,” says Wilson.
The Pratt Miller team may use the FARO ScanArm in their lab, on the production floor, in the garage, or on the road, whether utilising it for hard-contact probing, non-contact scanning, or a mix of both. This is possible because of the equipment’s portability, dependability, and versatility.
The C8.R will make its Le Mans debut, and Wilson says his team is eager to watch it battle against the top teams and manufacturers in endurance sports car racing in the GT Pro Class at the largest event in the sport.
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