3D Scanning for Advanced Manufacturing covers the methods and technologies that engineers and technicians need to know to use 3D scanning tools in their manufacturing workflow, with a particular emphasis on additive manufacturing. After introducing the basics of 3D scanning technologies, the book explains how to use different types of equipmentincluding handheld and arm mounted scanners, structured light scanners, CMM mounted scanners, spherical scanners, lidar, and photogrammetryand how they interface with software for data collection, inspection, and modeling. Subsequent chapters cover the use of 3D point clouds for data processing, post processing, and mathematical treatment. Each chapter contains real world case studies that walk readers through applications such as injection molding and as-molded parts, reverse engineering and validation of additively manufactured metal parts, large-scale scanning, and more. In addition to highlighting the skills and techniques used in these applications, the case studies will also address the cost- and time-comparisons that need to be made when selecting which scanning technologies to use for a particular job.

Gary C. Confalone, BSEE, MSME, is the CEO of ECM Global, a company specializing in 3D scanning and reverse engineering. He has spent the past three decades working in the metrology industry with the first half of his career focused on the development of laser-based measurement systems, and processes, for the aerospace industry. He has served as Chair for both the Coordinate Metrology Society and the 3D Certification Committee. Gary received a Bachelor's degree from the University of Massachusetts, and a Master’s Degree from Boston University.

John Smits, AIA VP of ECM AEC Division, John is a registered architect and one of the initial adopters of large volume 3D laser scanning technology as it applied specifically to the architecture, engineering, and construction professions. He has shared his expertise at trade shows and conferences, on-line webinars, and he has authored many publications in academic journals and trade magazines. John earned a Batchelor degree in Architecture from the University of Virginia and a Master’s degree in Architecture from Washington University in St. Louis.

Thomas Kinnare, BSME, is Principal Engineer and lead developer of the ECM Training Division. Over the past two decades, Tom has been instrumental in the advancement of 3D metrology practices throughout the industry, working to institute an international metrology education and certification training program. He currently serves on the American Society of Mechanical Engineers (ASME) Y14.45, GD&T Reporting Subcommittee, and the Coordinate Measurement Society Certification Committee. Tom earned his Batchelor’s degree from Massachusetts Institute of Technology.

Preface xi

How to Use This Book xiii

Chapter 1 History of Metrology 1

1.1 Introduction 2

1.2 The History of Metrology 2

1.3 The International System of Units (SI) 3

1.4 The History of the Metric System 3

1.5 The History of the British Imperial System (IS) 4

1.6 Evolution of Metrology 13

1.7 Milestones of Metrology 22

Chapter 2 3D Scanning Basics 25

2.1 Basics of Laser Light Technology 25

2.2 Laser Safety 25

2.3 So What Exactly Is a Laser? 28

2.4 Laser Types 29

2.5 LIDAR vs Laser-Radar 32

2.6 Laser-Radar 32

2.7 Basics of 3D Scanning 35

2.8 How It Works 35

2.9 Limitations 35

2.10 Accuracy 36

2.11 Modern Metrology 37

Chapter 3 Scanning Equipment 39

3.1 Introduction 39

3.2 Triangulating Laser Scanners 39

3.3 Data Acquisition Variables 41

Chapter 4 Data Acquisition and Processing Software 65

4.1 Introduction 65

4.2 Data Acquisition Software 66

4.3 Inspection Software 71

4.4 Data Export Options 72

4.5 Point Clouds 73

4.6 Processing and Registration 78

4.7 Survey Controls 80

4.8 Polygonal Mesh 81

4.9 Using Processed Datasets 82

Chapter 5 Post-Processing 85

5.1 Introduction 85

5.2 Coordinate Systems 86

5.3 Scaling 93

5.4 Mapping Techniques 93

5.5 CAD to Part Comparison 97

5.6 Root Mean Square and Standard Deviation 98

5.7 The Method of Least Squares 99

5.8 What Is Uncertainty? 102

5.9 Contributing Factors to Uncertainty 105

5.10 Typical Post-processing Workflow 108

Chapter 6 Reverse Engineering for Industrial and Consumer Applications 111

6.1 Introduction 111

6.2 Industrial Applications 112

6.3 Case Studies 118

6.4 Racing Yacht Boat Build 118

6.5 Reverse Engineering: Cessna Caravan Performance Upgrade 121

6.6 Replication of a Classic Propeller Design 123

6.7 Roller Coaster Inspection 126

6.8 Argomaiden Sculpture 129

Chapter 7 Reverse Engineering for Architecture, Engineering, and Construction 133

7.1 Introduction 133

7.2 Modeling for Architects and Engineers 134

7.3 Case Studies 142

7.4 Research Facility Coordinate Control System 142

7.5 Architectural Ornament Replication 146

7.6 Fonthill Castle, Bronx, NY 149

7.7 Infrastructure Preservation 153

7.8 Generating Station Turbine Replacement 158

Chapter 8 Future Directions 161

8.1 Software Development 162

8.2 Technology 162

8.3 Extended Reality 163

8.4 UAV and AV 165

8.5 Industry Trends 165

8.6 Summary 168

Chapter 9 Resources 169

9.1 Units of Measure 175

9.2 Coordinate Metrology Society (CMS) Certification 181

9.3 Certification Committee 181

9.4 CMS Certification Levels 183

9.5 CMS Level-Two Certification 185

9.6 National Metrology Laboratories and Institutes 187

Metrology Glossary 191

Index 201