Reverse engineering of huge machine parts in difficult locations with Artec Eva and Geomagic Design X

An international manufacturer of spare parts needed to create spare parts for a construction machine.

Artec’s Golden Category partner in Turkey has successfully completed a project to replace some old parts of a construction machine, which were milled with models obtained with Artec Eva, a high-precision portable 3D scanner for large objects.

The work was commissioned by Assan ASP, a well-known international producer and distributor of spare parts for work machines.

It would normally have taken Assan ASP a couple of weeks to measure and draw these parts, and some of the elements are quite difficult to measure accurately with traditional methods.

After a demonstration by Teknodizayn, Assan ASP directors saw that, in cases like this, it is significantly simpler and much faster to work with Artec 3D scanning solutions and Geomagic’s reverse engineering software.

The task was to duplicate two independent parts for a construction machine (traction bar set & circular mounting yoke) for future use. The parts needed to be accurately produced from the data obtained during 3D scanning and then mounted on the same type of construction machine.

“As we know, Artec 3D scanners are the best to be used in situations where a large part must be scanned in a place where conditions are difficult. This was precisely that kind of situation,” says Ali Can Boysan, Teknodizayn Sales and Technical Support Manager.

Ali had to scan at the manufacturer’s facility, using special security equipment. He used Artec’s Eva scanner along with Artec’s battery pack, as there was no immediate access to a direct power source.

“Freedom of movement with Artec’s drum pack was a big plus, as I walked around the parts,” ali says.

The parts had shiny, metallic surfaces, so those areas had to be sprayed before being scanned.

“Artec’s Eva was the appropriate scanner for this work as the parts were very large and the required accuracy was in artec Eva’s precision range,” says Ali. “The scan was quite quick and easy, considering that the parts were quite large, like 3 meters.”

Each part took 30 – 40 minutes to be scanned in detail (including the upper and lower parts).

“Those were quick scanning sessions,” Ali says. “No other scanner can measure such large parts so accurately and quickly.”

Once the scan was complete, Ali transferred the data to his computer in Teknodizayn’s office. Post processing each part in 3D imaging software, Artec Studio 11, took about 4-5 hours.

The data was processed manually. First the unnecessary parts of the scan were removed and then the scans were aligned using the quick and simple point-to-point algorithm. Then the Global Register with Texture and Geometry was applied, resulting in a dense and precise point cloud that had to be meshed. The next step was Fine Fusion with the best possible resolution, creating a .stl mesh of models ready to be used in reverse engineering.

The files were exported to geomagic Design X reverse engineering software. “This is without a doubt the best, fastest and easiest program among its competitors,” says Ali. “Our reverse engineering specialist first self-established the parts and then aligned them to coordinate the plans. Then, parametrically, he drew the solid models precisely, characteristic by feature. After 7-8 hours of working on each part, solid models were ready to be produced directly.”

Manufactured parts achieve the required accuracy. They were installed and tested on a construction machine, and fit perfectly. Assan ASP was impressed with the result and acquired a combo of Eva from Artec, Space Spider and Geomagic for SOLIDWORKS CAD to improve their traditional workflow and use the technology in future R&D.