Based in South Korea, Autocut is an automotive paint protection film (PPF) and tinted film solutions provider. It delivers software with 17000+ pattern data of paint protection films (PPF) and pre-cutting films for automotive aftermarket shops. Pre-cutting of the film based on the shapes of car parts is needed for productive PPF projects. With over 15 years of expertise, Autocut’s solutions are adopted in over 100 shops in South Korea.
Traditionally, Autocut’s development team performed measurements manually, using tape and transparent paper, in order to design new patterns. Film cutting was also carried out by hand. Unfortunately, these processes did not provide consistent results as the patterns tended to vary based on shop floor conditions. Large patterns, which couldn’t be covered by paper and film, were difficult, if not impossible, to make.
Autocut’s digital transformation: The search for the right 3D scanner
Sangwon Jung, Autocut’s CEO, and Chango Kim, Director, decided to look for a more modern alternative and transition towards digitalization. “We wanted both hardware and software that were easy to use and reliable,” explained Jung.
The team looked into several 3D scanning technology vendors; unfortunately, after extensive testing, the quality of the scans was poor, and the software platforms were not very intuitive. Some of the scanners could not even show a clear image because of severe reflections or distortion of colours on the boundary lines.
Creaform’s 3D scanners take on Autocut’s most challenging projects
Autocut then took Creaform’s metrology-grade 3D scanners for a test drive. “Creaform’s solutions were different,” Jung said. “They are very user-friendly, and the software is equally easy. We knew right away that we could deploy these solutions very quickly into our existing workflows.”
The company acquired Creaform’s MetraSCAN 3D and Go!SCAN 3D scanners, along with VXelements software, an advanced 3D metrology software platform. The results were almost immediate. Technicians can quickly scan a vehicle and get the 3D measurements they need in a very short timeframe. Jung and Kim estimate that the 3D scanners have improved efficiency twofold.
Creaform’s 3D scanners also drastically reduced repetitive tasks. “Once the components are scanned the first time, it is simple to expand and modify them with additional new patterns—all while ensuring consistency,” Kim added. This means that technicians can derive as many patterns as they want by analyzing and substituting various 3D models. Autocut also observed major efficiency gains when it came to highly customized film cutting for specific cars, which inevitably allowed the company to take on even more projects.
Contrary to other 3D scanners on the market, MetraSCAN 3D and Go!SCAN 3D generated clean and accurate data in real time without any limitations, including white, black, shiny and reflective surfaces. Complex geometries could also be captured with ease. In addition, VXelement’s post-processing capabilities accelerated development thanks to the software’s versatile features and fast treatment.
“We were very happy with the immediate technical support and continuous software updates,” Jung said. The team was able to rely on Creaform’s responsive local experts for any questions or troubleshooting—a must for businesses that are just starting out with 3D scanning technologies.
Autocut plans to expand into other sectors in the short term by offering services for motorcycles, bicycles and golf clubs. “We believe that thanks to Creaform’s 3D scanners, our business has greatly improved customer satisfaction and helped us to gain a competitive edge in our market.”
The Chair of Metal Structures at the Technical University of Munich has been contributing to the development of steel and light metal structures within the construction industry for many decades. There is a long-standing tradition in the areas of bridge design, stability, construction, composite structures, fatigue and glass works. However, other current matters are also continuously addressed, and new priorities are set. In recent years, research efforts in fire and explosion safety have intensified, thus requiring highly complex numerical investigations in addition to experimental validation.
Measuring System Requirements and Challenges
Given their experimental approach supplemented by numerical experiments, the Chair expressed great interest in the exact dimensions of the test specimens—in this case, columns. They would later be used as reference for inspections. The measurement tasks for test specimens were often outsourced. For one thing, this was very costly and therefore restricted 3D measurements to isolated test specimens.
The following criteria played a decisive role in the search for a 3D measuring technology: Precision, workability of the measured data in widely used civil engineering software, easy-to-use functionality, as well as short scanning and inspection time. Based on various factors, the decision was finally made in favor of the HandySCAN BLACK from Creaform. This portable 3D scanner distinguishes itself from other devices on the market by its wide range of measurement possibilities, the compatibility of the data with common CAD software, its already proven and widespread use in well-known companies, and a compelling product design.
Scan of Heavy-Duty Composite Column Geometries
In order to identify misalignments and curvatures of high-strength composite columns, geometric imperfections had to be scanned. Unfortunately, columns are not always perfectly straight. Deviations from the ideal shape often occur during production. These deviations are known as imperfections, and they have a variable influence on the bearing load of the component, depending on how far from the ideal shape the deviations are. For components subject to compressive stress, these imperfections lead to a reduction in the bearing load capacity, which depends on the degree of deviation. By measuring them with a 3D scanner, we can obtain important information about the dimensioning of the components.
Columns of up to 4 meters long can be scanned relatively easily with the HandySCAN 3D. Positioning targets are placed on the pipe and the pipe is placed in an upright position. This allows the contour to be measured quickly and easily from all sides—including the curved cylinder surface and the cross-sectional contour at the end of the pipe.
The 3D measurements provide information about the imperfections of the component. However, the component had to be modeled separately in an finite element (FE) environment and given equivalent imperfections that represent not only the geometric, but also the structural imperfections. The calibration of these equivalent imperfections is based on the scan and test results. After a period of adjustment, the scans were assessed in VXinspect. Dimensional inspection software such as VXinspect facilitates analysis by means of built-in functions; in the case of pipes, for example, cylindricity is important.
Scan and CAD of a high-strength composite column with color deviation
The impact of the internal stresses and imperfections incorporated in the finite element models can now be quantified with measurements before they actually appear. This avoids resorting to benchmark values, and calibrating these variables afterwards according to the experiments conducted.
“Creaform greatly facilitates and enriches our research in the field of steel construction, and will prove indispensable in any experimental project in the future. Since we also have our own 3D scanner, we can now measure a large number of test specimens ourselves. This results in greater flexibility, and considerable cost savings, since we no longer need contractors,” says Prof. Martin Mensinger, Head of the Chair of Metal Structures at the Technical University of Munich.
Product: HandySCAN Industry: Aerospace and Defense
Lufthansa Technik AG (LHT) is a provider of MRO (maintenance, repair and overhaul) services for aircraft and has 50 locations worldwide. LHT is wholly owned by Deutsche Lufthansa AG and comprises 32 technical maintenance companies and subsidiaries in Europe, Asia and America, along with more than 26,000 employees (as of 2019).
LHT is based at Hamburg Airport. Other important German locations are the two Lufthansa hubs Frankfurt Rhein-Main and Munich as well as the Berlin Tegel Airport (Line Maintenance) and Schönefeld (C-Checks).
Control of Material Expansion
The ARC® – Airframe Related Components division overhauls and repairs fan reversers, engine cowlings, flight controls, aircraft noses (radomes), and other secondary structure composite components. In addition to maintenance work, repair, developments, all types of material support, and logistics solutions are provided. These services are offered for civil aircraft and nearly all popular aircraft types.
To repair the above-mentioned components, adhesive trays made of carbon or glass fiber are used. Shapes and contours must be checked regularly. The production process takes place under the influence of pressure and temperature variations in an autoclave, so that the material can expand. The extent of the expansion is determined by periodic scans. It is not a one-off project—but a regular measure to ensure quality standards.
Screenshots of a scanned aircraft nose
The actual state is checked with Creaform’s HandySCAN 3D scanner or, for large objects, with the photogrammetry camera MaxSHOT 3D and compared with a CAD model (target state). On the software side, the data acquisition software, VXelements, is used for data acquisition. On top of providing reliable measurements, Creaform systems are used for other applications, such as reverse engineering, with the help of VXmodel scan-to-CAD software module.
Decision Criteria and ROI
Before LHT started using Creaform systems, measurements, data processing and reverse engineering were provided by a third-party company. The quality of the data as well as the duration of implementation and flexibility in changing conditions led to the decision to purchase hardware and software, thereby building the company’s internal know-how.
Decisive for the choice of the measuring systems were the compactness of the devices as well as the simple data acquisition with the HandySCAN 3D scanner. With these key features, it is possible to capture complex geometries with relatively little effort. In addition, the accuracy for the intended applications is sufficiently high. The MaxSHOT 3D helps to ensure unprecedented accuracy even for larger objects. Currently, the measurement systems are used exclusively in a workshop environment under (mostly) controlled, climatic conditions.
Photogrammetry camera MaxSHOT 3D measures large objects with high accuracy
“The control of the material expansion could have been measured with other common measuring systems, but the price-performance ratio and the compactness of the 3D measuring systems from Creaform made the decision easy. In addition, the customer service is impeccable,” explained Gunnar Hinrichs, who works at the Airframe Related Components Department at LHT. “In terms of ROI, the purchase has also paid off, even if we do not yet have any meaningful data. But it is likely, according to our own estimate, to have a give-figure amount in the lower segment, which we save on outsourcing. If we detect quality deviations at an early stage by using the Creaform technology, we can prevent unnecessary costs and therefore expensive reworking at the customers’ sites.”
Compact, Simple and Flexible
The experience with the Creaform systems is positive. “We can respond much faster and more flexibly to measurement tasks, discuss the measurement results directly at the measured component, and share information with other stakeholders. The systems consistently convince us we made the right decision with their compactness and simplicity of use. A measurement process, including pre- and post-processing (assembly, attachment of the targets, etc.), is completed within 2-3 hours. The data is available in real time. The software interface is well-implemented, understandable and clear. The training provided by Creaform is outstanding and the employees are always available for advice and support. That’s the way you want it to be,” said Hinrichs.
Product: HandySCAN Industry: Aerospace and Defense
US Department of Defense Uses 3D Measurement to Solve Maintenance Challenges
The United States military sector is faced with a host of technical challenges when it comes to maintenance, repair and engineering. Aircraft only have value if they are flight worthy. Personnel responsible for this need efficient and effective means to reduce risks, costs, and maintenance turnaround.
3D scanning instruments and technologies remedy discrepancies due to user errors, they allow for time-saving MRO and reverse engineering operations, and are effective for providing CAD files for 3D-printed replacement aircraft parts and prototypes.
Metrology Hardships in Military: What Can 3D Measurement Do to Help?
Tech. Sgt. Kevin Collins, 366th Maintenance Squadron aircraft metals technology section chief scans an aircraft structure at Mountain Home Air Force Base, Idaho, March 2, 2020. The HandySCAN 3D allows Airmen to scan a structure, eliminating the need to hand draw it on the computer. (U.S. Air Force photo by Airman Natalie Rubenak)
Heavy aircraft maintenance often means long-term grounding, resulting from errors in custom repairs.
Since reliable CAD data is typically not available, the aircraft must be measured to make repairs. Measurement discrepancies typically result from the lack of adequate tools to measure multiple objects and complex surfaces in addition to the challenges to inspect a wide range of part sizes, finishes and colors.
In a nutshell, 3D scanning devices and technologies can be used to accelerate reverse engineering, MRO operations and 3D printing applications, thus increasing mission effectiveness.
Reverse Engineering – Manual to Digital
MRO – Streamlining Inspection and Structure Damage Analysis
Align and Mate: The Bell Helicopter Case
Reverse engineering process: From manual to digital
The 366th Maintenance Squadron (MXS) at Mountain Home Air Force Base (MHAFB) acquired a Creaform HandySCAN 3D handheld 3D scanner to scan large aircraft structures quickly and efficiently.
Prior to using the device, MHAFB Airmen would use “facsimile mold” to fix broken parts or recreate structures. The main issue with facsimile mold is that it takes 48 hours to dry. “When it is done drying, you take it out and still have to go in and measure everything and hand draw it on the computer. It [is] so time consuming,” says Tech. Sgt. Kevin Collins, 366th MXS aircraft metals technology section chief. This tedious reverse engineering process consisting in manually designing models on the computer puts the personnel at the mercy of user errors and premature maintenance.
3D scanners provide the data required to perform full-scale engineering, manufacturing and development of parts and structures. 3D scanning for reverse engineering removes the user error factor and provides unmatched traceability for documentation purposes. Also, device portability means on-site analyses, and reduction of inspection times. 3D scanners are critical tools to support solid reverse engineering processes.
The model above was scanned using a HandySCAN BLACK portable 3D scanner; you can zoom in and see the level of detail around the edges, the holes, the bends and the fasteners. This complex, large part (680 mm X 320 mm X 60 mm) displays several features which would be difficult to measure without 3D scanning instruments.
Another problem faced by MHAFB Airmen is that of accuracy. The mold would often provide little to no accurate results, which would eventually lead to rework and wasted time. “With the scanner, we never run into that issue. In fact, it’s accurate up to about 0.025 mm,” Collins said.
Parts manufactured following this type of reverse engineering process can be quickly and accurately compared to CAD drawings to control 3D dimensional quality.
2. MRO – Streamlining Inspection and Structure Damage Analysis
Fairfield’s Travis AFB, via the 60th MXS, reported using various innovative strategies to improve mission effectiveness and reduce wasted time. The Air Force allocated $64 million in Squadron Innovation Funds to “increase readiness, reduce cost, save time and enhance the lethality of the force,” said Joshua Orr, 60th MXS. Among the new technologies were 3D printing and 3D scanning; the former using the latter to print and replace aircraft parts that suffered damage.
In one notorious case, a C-5 aircraft had been damaged by hail, resulting in numerous dents and scratches on all of the plane’s panels. Every 180 days, Travis Airmen would inspect the aircraft to locate and measure the dents that were still on the wing’s surface. Using traditional measurement tools and methods, performing this task would take around 48 hours. But equipped with a Creaform HandySCAN 3D and SmartDENT 3D, the Airmen were able to complete the inspection in 30 minutes. Unlike manual dent measurement methods, SmartDENT uses good material around damage to create reference surface and provide reliable measures.
Joshua Orr, 60th MXS, uses a Creaform HandySCAN 700 to capture digital information to render a three-dimensional image of an aircraft part into specialized computer software.
“We had that C-5 in our hangar last week and we were able to inspect the four primary structural panels in 30 minutes.”
Master Sgt. Christopher Smithling 60th Maintenance Squadron assistant section chief for aircraft structural maintenance
Moreover, the procurement of two additive manufacturing units by the 60th MXS will undoubtedly unlock development, repair, replacement and production capabilities at Travis AFB. Aircraft are typically down for two days when a replacement part is needed. However, a solution comprising a 3D scanning device, scan-to-CAD technology and 3D printing can dramatically decrease out-of-service time. “With the two additive manufacturing units, we will be able to grab any aircraft part, scan it, and within four to eight hours, we will have a true 3D drawing of it that we can send to the additive manufacturing unit to print it,” said Christopher Smithling, 60th MXS.
Back to the hail storm matter, Creaform developed a complete 3D scanning solution for the aerospace industry named HandySCAN AEROPACK. It addresses the specific challenges of aircraft quality control, such as assessing damage resulting from aircraft incidents and natural phenomena, like hail, as well as flap and spoiler inspections. The 3D scanner and software package includes VXinspect, VXmodel, SmartDENT 3D and provides the most versatile solution for a maintenance base/MRO facility.
Leading edge of stabilizer of a Boeing 767 damaged by hail3D scan of the leading edge of a Boeing 767 aircraft using a 3D scannerAnalysis of leading edge of a Boeing 767 stabilizer in SmartDENT 3D. Total analysis/reporting time is 30 minutes for full stabilizer damage assessment with a 25-micron accuracy compared to 1-2 days with traditional manual methods.Sample dent inspection on an aircraft. Feature measurements with out of tolerance maximum depth.
3. Align and Mate: The Bell Helicopter Case
At their Amarillo factory in Texas, Bell Helicopter, a Textron Inc. company, performed the mating of heavy components with the V-280 Valor’s fuselage, a medium-lift tiltrotor transport prototype aimed at “[rekindling] the Army’s interest in tiltrotors.” First, nacelles were attached to the wing, and then the nacelles-wing assembly was attached to the fuselage. These complex operations require vivid attention to detail, bearing in mind the extreme accuracy with which the massive components must be oriented and positioned prior to the mating process.
Multiple C-Tracks and the Creaform VXtrack software module for dynamically tracking multiple objects came in handy to accurately measure the position and orientation of the components of this assembly in real time, as they are assembled (in this case, the tiltrotor’s wing, nacelles and fuselage).
V-280 Valor wing mating at Bell Helicopter Amarillo. Photo courtesy of Bell Helicopter.
Bottom line, the benefits of 3D technologies along with dedicated software are direct and substantial over conventional metrology. Components were positioned in hours, rather than days. Time savings on measurements, increased accuracy, removing user error and unmatched traceability, are just some of the benefits of state-of-the-art measurement technology.
MRO: How to Choose the Best 3D Measurement Solution?
To choose the right 3D measurement solution for your maintenance, repair and engineering project, start by mapping out your current 3D measurement or inspection process, and identify the major, most recurring problems of your workflow and opportunities for improvement.
Of course, accuracy, portability and price all make great impact on decision making, but the more information you can get about the target application and the results you want to generate, the better your choice will be.
Considerations with respect to object dimensions, environment, processing speed and software compatibility will help you find the solution that best fits your needs. That way you will probably be able to start simple and scale things up along the way.
For instance, decision-makers in the aerospace MRO industry will tend to orient their choice based on the fact that the objects to scan are relatively large, that the environment greatly affects the surfaces, and that time is of the essence: the longer aircraft are grounded, the more stakeholders lose money.
Do not hesitate to reach out to various providers to ask for a demonstration and discuss your current challenges with 3D measurement specialists. Creaform offers a full suite of 3D solutions for this type of work: metrology graded, truly portable, fast and versatile. We maintain an ISO 17025 accredited in-house calibration laboratory and can provide unmatched support across the world. Creaform offers traceable solutions that will provide you measurements you can rely on.
Product: HandySCAN Industry: Aerospace and Defense
EADS (European Aeronautic Defense and Space company) is a worldwide leader in aerospace, defense, and associated services. The company has been using Creaform portable 3D measurement products for several years.
More specifically, EADS uses both the HandySCAN 3D and the MetraSCAN 3D optical CMM scanner for scanning tooling and composite parts (carbon/epoxy) and for making parts/CAD comparisons. For its probing needs, EADS uses the HandyPROBE optical CMM. In addition to using VXelements, the data acquisition software behind all Creaform systems, EADS additionally uses the VXtrack module for dynamic measurements, as well as VXlocate, a software module developed through a partnership between Creaform and EADS.
HandySCAN 3D Application Example
As part of a study on the possible geometric distortion of carbon fiber composite parts and with the help of a HandySCAN 3D device, EADS scanned a 1 000 mm x 800 mm tooling equipment, as well as 650 mm x 300 mm parts, to assess post-manufacturing deformation.
Parts on tooling
First, EADS scanned the tooling, in order to verify its compliance with the CAD plan.
Scanning the tooling with the HandySCAN 3D
Then, two parts manufactured with this tooling were scanned, and the scanning files were compared.
Scanning the parts and results
Results: tooling/parts gap
The second step consists of using very powerful simulation tools to estimate the distortion of the parts before manufacturing, in order to compare the manufacturing parts scanning files.
Simulation
The results EADS obtained made it possible to validate the simulation software, which was developed to optimize the manufacturing range by identifying adequate parameters and processes.
This project could have been completed with a fringe projection scanning system, but the one EADS owns cannot be used for such large surfaces, and the process is a lot more complex when it comes to measuring the two faces of the composite parts. Additionally, a CMM could have been used, but this possibility came with two drawbacks: one-off measurements, which in turn lead to a much longer acquisition time.
“ The Creaform system enabled us to quickly scan the metallic tooling and the carbon fiber composite parts. Many other systems that are available on the market do not work very well on these composite parts, which aspect is very dark and sometimes very glossy. The equipment being so portable made it possible for us to record the measurements right at the manufacturing site,” explained Ms. Catherine Bosquet, from the EADS Structure Health Engineering (NDT & SHM) department.
“ Before using Creaform’s systems, we used fringe projection, since we purchased a HOLO3 system over 15 years ago. We also tested other available systems (Konica Minolta, Metris, Steinbichler, Aicon, Kreon Technologies, Ettemeyer, GOM), but the Creaform 3D measurement solutions convinced us, because of their quick set up and acquisition, ease of use, measurement performance for many types of surface states, as well as their portability.We must also mention that Creaform experts are always highly available and responsive.”
Product: HandySCAN Industry: Automotive and Transportation
“The Creaform solution is highly accurate, easy to use and well-suited to a production line environment. Having the system ready at hand gives us the flexibility and response time we need to quickly investigate measurement and quality issues as they arise.”
Swedish design and visionary technical solutions: that’s the way Koenigsegg works.
The Swedish company Koenigsegg Automotive AB is the market leader within the elite hypercar market, developing and hand-building advanced artisan vehicles since 1994.
The journey of Koenigsegg, since its inception, is truly incredible. It all started on August 12, 1994 when a young man, aged 22, set out to realize his childhood dream. He was a young man fuelled by passion, ingenuity and mind-bending will. Christian von Koenigsegg had just made up his mind to live his dream and start his own car company. The odds were stacked against him. It was a now or never moment. His idea was to create a sports car that he felt did not currently exist and one which he believed would be desired—two essential necessities for success, Christian felt.
The concept: A lightweight mid-engine car with a detachable, storable hardtop. The car would also feature a wrap-around screen for good visibility and aerodynamics as well as short overhangs with two large intercooler intakes on the side of the car, located behind the mass centre to aid high-speed stability. The car would look and feel good with the top up or as a roadster—transformed in minutes with the hard top neatly tucked away inside the car. Christian envisioned a car with a timeless appearance that aged like good wine. This was a mid-engine car concept that did not exist at the time.
Every Koenigsegg created since then now includes this simple, but effective, DNA attuned to Christian’s original vision.
Five production models with as many Guinness production car records later, Koenigsegg has exploded onto the international scene and is here to stay. When Christian is asked what his greatest achievement is, he says without hesitation: “Living the dream!”
Measurement tasks and equipment
The day Koenigsegg got in touch with Creaform, the company was using rental services for measurement tasks. A four-meter Romer Arm with scan and probe heads or a Leica Tracker together with PolyWorks were employed. The measurement and scanning systems were primarily used for root cause analysis on the production line, comparing physical parts to nominal CAD as well as for fixture set-up, commissioning and reverse engineering tasks in which handmade parts were replaced by and CAD data produced using Catia V5R19 for production tooling and manufacturing.
Frequent functional downsides of the rental equipment, substantial expenses and time constraints as well as the goal to have in-house 3D measurement skills, brought Koenigsegg to start looking for alternatives on the market. Creaform’s Swedish reseller, MLT Maskin & Laserteknik AB, went to Koenigsegg for an on-site demonstration of Creaform’s 3D measurement technologies.
“After benchmarking all available measurement systems, we felt that Creaform products and solutions fitted best with our demanding requirements and environment. Being less sensitive to movements during scanning and probing, the Creaform’s solutions are better-suited to a production line environment,” explained Jon Gunner, Technical Director at Koenigsegg. “We decided to invest in the HandySCAN 3D scanner and portable optical CMM HandyPROBE from Creaform and the CAD and inspection software called PolyWorks.”
HandySCAN 3D metrology-grade scanners can capture up to 480,000 measurements/s with an accuracy of up to 0.030 mm.
The handheld HandySCAN 3D laser scanners provide breakthrough accuracy and resolution as well as significantly high measurement rates—all in a single, portable device. They can be used in all phases of the product life cycle: from conception, through design, manufacturing up to documentation, maintenance and repair purposes.
Free of any rigid measurement setup, HandyPROBE offers unmatched flexibility and a wider measurement volume than other portable CMMs.
The HandyPROBE portable CMM arm-free measurement system is the alternative to traditional measurement arms. The HandyPROBE is a wireless, triangulation–based CMM that offers complete freedom of movement and can be used for single or repeated measurements of various parts. The CMM is tracked by C-Track optical tracker. C-Track sensors also ensure the exact position of the HandyPROBE, perform continuous image acquisition and transmission, provide lighting of reflectors, manage exchanges with the computer, and store sensor parameters.
Both systems benefit from the integrated TRUaccuracy technology, which ensures highly accurate measurements when operating under real working conditions—regardless of vibrations, instabilities or thermal differences in the work environment.
How Creaform technologies intervene
The HandySCAN 3D scanner and the portable CMM HandyPROBE are now primarily used at the Swedish company for automotive quality control, measuring assemblies and components, and validating them to CAD as well as for root cause problem solving, reverse engineering and jig calibration. For jig calibration, Koenigsegg uses, for example, the probing system HandyPROBE to accurately adjust the nominal hard points. Then, users scan with the HandySCAN 3D scanner the parts once they are held by the jig as a validation process against the CAD data. This allows the company to trim the jig if a nominal offset should be required.
For quality control or engineering projects, HandySCAN 3D enables users to reduce turnaround times and increase profitability. Shown above scanning the body of a Koenigsegg Regera.
Jon Gunner is happy with the in the Creaform systems: “Already six months after the purchase, I estimated that we were halfway to gaining a return on our investment based on third-party rental fees and improvements to production quality. Creaform’s solutions are highly accurate, easy to use and ideal for a production line environment. Having the system ready at hand gives us the flexibility and response time we need to quickly investigate measurement and quality issues as they arise.”
Product: HandySCAN Industry: Consumer Products and Retail
Flatz GmbH from Lauterach, Austria, is the market leader for system solutions in the packaging sector and produces corrugated board, insulating solutions, EPP moldings, and pull containers.
For its quality control workflows, Flatz faced the challenge of having to accurately measure increasingly complex contours of technical components, particle foams, and tools. The surfaces can be matte to glossy, with part sizes ranging from 100 mm to 2500 mm. Therefore, the company decided to acquire modern measurement technology to meet a complete range of quality control requirements.
The HandySCAN BLACK Elite from Creaform was the perfect solution. This portable 3D scanner can be used flexibly with an accuracy of 0.025 mm. It can also quickly and accurately measure components of any size, with matte to glossy surfaces in real time. Prior to acquiring Creaform’s new measurement system, Flatz used tape measures, calipers, U-bolts, and similar tools to take measurements.
Bernhard Guldenschuh from Quality Management remarked: “We received excellent training from Creaform, which directly addressed our measurement requirements. We were able to quickly put together a team that can now take measurements on a wide variety of components at any time, if required. Product approvals can now be carried out without any problems.”
EEP part approval
Flatz GmbH had received an order to produce an expanded polypropylene (EPP) part with a size of approximately 250×300 mm for a new customer. It was to be installed on an injection-molded part. EPP is a thermoplastic material that is particularly environmentally friendly and easy to recycle.
The finished EPP part was mounted on an injection-molded part, which was then to be built into a complex device. The EPP part was designed to protect the interior of the injection-molded component. After sampling, however, there were problems with the fitting accuracy of the part. The customer was unable to install the part. The EPP part produced was scanned with the HandySCAN 3D and compared against CAD data in PolyWorks. It quickly became clear that the injection molded part had the wrong dimensions. It was subsequently adjusted and the EPP part could be installed.
Areas of application for the HandySCAN BLACK at Flatz
The HandySCAN 3D has become an integral part of the sampling and approval process of components at Flatz. It is used for technical component assessments, inspection of complex tooling, and checking dimensional accuracy. It can be used to quickly verify that a part fits, and provide results on part accuracy.
Product: HandySCAN Industry: Automotive and Transportation
How Hyundai Design North America uses HandySCAN 3D for improving real-time design workflows
Opened in January 2003 and located in Irvine, California, Hyundai Design North America’s design and technical center is a 90,000 square foot, $30 million state-of-the-art facility where automobile designers, engineers, model makers and other experts create new vehicles. The team offers alternative designs for its parent company based in South Korea.
As is the case with the vast majority of automotive manufacturers, clay sculpting plays a vital role in the design process in Hyundai Design North America’s studios in order to fine-tune concepts based on scale models and full-size clay vehicles. Clay modelling to design vehicles is still a very common practice with today’s automotive manufacturers to assess design quality and get feedback from reflection-based surfacing.
However, with today’s amplified competition for consumers as well as manufacturers’ accelerated time-to-market development and production schedules, design teams are under increasing pressure to create concepts faster than ever before. Digital modeling using 3D measurement technologies, such as portable 3D scanners, has become a vital solution in order to speed up design workflows.
Legacy 3D scanners no longer fitted the performance bill
For a long time, Hyundai Design North America, which is an early adopter of new technologies, used 3D scanners as a complement to its clay modeling and design processes. Unfortunately, at one point, the team realized it was time for a major equipment upgrade.
“The scanners that we were previously using were too bulky and difficult to manage. The scanning process and post-processing times were long and required most modelers to step away from working on the clay,” explained Rob Homer, Operations Modeling Manager at Hyundai Design North America. “This led to crucial time loss, especially when deliverables had hard target dates.”
Rob and his team began checking out available 3D scanners that fit their requirements. “We wanted a 3D scanner that was compact, easily portable, fast and accurate. It also had to be compatible with our CAD software.”
HandySCAN 3D: A clear front-runner in 3D scanning for designing vehicles in the automotive industry
“After looking into the various 3D measurement technologies out there, Creaform came on top for me with its HandySCAN 3D. It is a very good and reliable product at a very good price point,” Rob added. He was equally impressed with its ease of use and speed.
Hyundai Design North America was able to seamlessly implement HandySCAN 3D into its existing design workflows for real-time development. Training users on the software was completed in a day. “The experience from purchasing the scanner to training was incredibly pleasant and professional.”
Once the 2D sketch is settled, digital modelers get to work on the 3D clay models and mill it out for verifications and fine-tuning. Changes are performed by hand on the clay model, which is then 3D scanned to acquire the digital representation of the modifications.
“The scanning process is quick and easy. We are able to scan selected areas of the model without disturbing anyone working around it,” he said. “We can relay information to the digital team within minutes after finishing the scan.” This quick turnaround time of the scan data to the digital modeler means that affected areas can be fixed quickly to mill the model again before final reviews.
Richard Gillespie, Senior Digital Modeling Manager, says that the 3D measurements enable the modelers and design team to know exactly where the clay models are landed in comparison with design criteria and styling boundaries. They can quickly identify and correct discrepancies. Designers can come to decisions faster thanks to the efficiency and accuracy HandySCAN 3D offers.
One of Rob’s favourite aspects is HandySCAN 3D’s simplicity. “My modeling team can use it independently without having to wait for another expert to do the scans for them. That makes our services a true one stop shop.”
Hyundai Design North America will continue to improve their clay modeling workflows using 3D scanning in order to allow more time for the design process and refinement. We look forward to seeing the new designs hit the market!
Product: HandySCAN Industry: Consumer Products and Retail
With its leading solutions in the fields of testing and measurement, technology systems, and networks and cybersecurity, Rohde & Schwarz, a technology company based in Munich, is one of the pioneers of a more secure and networked world. Founded more than 85 years ago, the group is a reliable partner for its customers in industrial and government sectors around the globe.
HandySCAN 3D for the Rohde & Schwarz Teisnach plant
The Teisnach plant is a system supplier and center for mechanical and electronic manufacturing within the Rohde & Schwarz network. Among the products manufactured at the plant are body scanners, housings, printed circuit boards, TV and radio transmitters, customer-specific wireless communications systems, micromechanical precision parts, and electromechanical custom products of all kinds. As a contract manufacturer, manufacturing services are offered as part of the complete range of services from product and software development to after-sales service.
As broadly diversified as the Teisnach plant is, so too are the measurement tasks, which can range from quality control workflows in the company’s own production lines to complete reverse engineering tasks for additive manufacturing projects.
A flexible 3D measurement system was to be introduced at the Teisnach plant in order to be able to supplement the range of services offered by the internal quality assurance department. The goal was to find a measuring tool that would offer the greatest possible flexibility in measurements as well as in terms of its applications: quality control, the measurement of vehicle interiors for modifications, inspections of free-form surfaces, and additive manufacturing processes. The aim was to achieve a high level of accuracy at all times. In addition, the team was looking to reduce inspection times as well as implement a faster and easier method to create 3D models.
Accuracy requirements also included being able to objects ranging from the size of a 10x10x10 mm cube to the vehicle geometry of a jeep, with a required accuracy of up to 25µm.
The HandySCAN BLACK | Elite from Creaform met all the requirements the measuring system and was integrated as an extension to the range of quality assurance services at Rohde & Schwarz, where other stationary tactile and optical measuring devices are already in use.
The decisive factor for selecting Creaform’s 3D scanning solution was the wide range of applications it could handle and following features:
High accuracy and fast acquisition of free-form surfaces and large components as well as quick assessment of the scan data. Thanks to non-contact scanning, highly sensitive surfaces and contours are never damaged—contrary to when a touch probe is used to inspect parts, such as gold-plated components.
Older or damaged stamping or injection molding tools for which no 3D data set is available can now be scanned. The generated scan data can be used to generate CAD model sand reproduce the tools.
Flexibility, precision and user-friendliness in handling the 3D scanner
Due to high scanning speeds, the amount of time needed for the design of vehicle interiors has been reduced from 1 working day to 2 working hours.
summary
The HandySCAN 3D is regularly used in the Teisnach plant. Operators carry out 3D measurements in the dedicated measuring room, directly in the workshop for component inspections, and at customer sites.
“Due to the portability and high level of accuracy of the HandySCAN BLACK | Elite, we create added value for our customers that would not have been possible with our existing equipment. The Creaform system is extremely versatile and represents a great improvement for us, especially for the construction of special-purpose vehicles. For example, we can now accurately and quickly measure vehicle interiors for adaptive designs. In addition, we can efficiently check free-form surfaces with the scanner. The excellent service and support provided by Creaform should also be underscored. Overall, we are very satisfied,” said Josef König, Head of Quality Assurance/Testing Technology at the Rohde & Schwarz plant in Teisnach.
Product: HandySCAN 3D Industry: Automotive and Transportation
Aftermarket: 3D scanning as a preliminary step in the production of prototypes and samples of accessories for custom bikes
ABM Fahrzeugtechnik GmbH has been developing high-quality accessories for motorcycles of all the established brands with passion for over 30 years. Their focus is on ergonomics, modern technology and German safety standards. At ABM, unsurpassed quality meets striking design for ergonomic driving fun. Under the umbrella of ABM Fahrzeugtechnik GmbH, the WUNDERKIND custom brand develops premium accessories for custom bikes – such as motorcycles by Harley-Davidson, Triumph, Indian, Victory and others.
Rear fender conversion of a BMW R18
A complete conversion was required for the rear of the newly launched BMW R18. Instead of the original rear fender, a narrow, tight-fitting fender, which can be mounted on the rear wheel swing arm using retaining struts, was required. The original seat was removed and replaced by a free-standing seat.
In order to attach the license plate, an adapter also had to be designed to make it possible for a license plate holder frame to be mounted on the side of the swing arm. To this end, the motorcycle was first scanned completely and then without the original parts with the Creaform HandySCAN 3D scanner. Particular attention was paid to the exact position of the attachment points on the frame and the swing arm where the parts developed by ABM would later be mounted. Thread positions (M6 –M10) and hole spacing had to be captured with the utmost precision.
The scanned data could then be exported to the Solid Edge design program and used there as a basis for the design. The prefabricated fender was also scanned and placed in the assembly, concentric to the wheel. The struts and adapters could be designed directly on the model and then printed to be checked.
The position of the free-standing seat could be moved in the model and optimally aligned without the need for multiple mounting and dismounting of the individual parts. After the printed parts had been checked, production of the prototype and sample could begin immediately.
Scan imported into Solid Edge (red) and new rear fender including license plate holder (black) Below: Motorcycle with scan data
Process improvement
Before scanners were used, it often took a long time to record all the data and to measure and document components, which meant the customer’s vehicle had to stay on site for a long time. With the Creaform scanning system, data is quickly recorded and documented. Components can often be prepared and printed digitally. All that is required is to have the vehicle in-house again for assembly and testing of the printed or manufactured parts. There are no unnecessary journeys between the workshop and the design office. By and large, the development process up to the finished product is significantly shortened, which saves time and money.
Another advantage is that the archived data can be used for further developments at any time without the vehicle having to be physically present.
Before the HandySCAN 3D scanner was acquired, measurements were made manually at ABM using calipers, measuring rods and measuring tapes. The procedure was extremely lengthy and the measurement results inaccurate, so that subsequent work on the model had to be performed repeatedly and 3D printing had to be carried out several times.
With this initial yet common measurement method, the project described above could have been implemented, but it would have been very cumbersome and several time-consuming and costly printouts would have been necessary due to trial & error. In addition, customer vehicles would have had to be available for a long time to implement the development.
ABM fully appreciates the advantages of HandySCAN 3D: highly accurate and reliable measurement results, small measurement distance (helpful in tight spaces), hardly any scan spray required (there is no need for laborious removal after scanning), easy handling of the scanner and software.
Photogrammetry camera MaxSHOT 3D measures large objects with high accuracy
