Dimension control of car mats based on 3D scans
Calibry is a lightweight, compact 3D scanner that is designed to scan medium to large objects. With its help, we made a project regarding the dimensional control of car mats based on 3D scans.
Dimension control of car mats based on 3D scans
One of the most interesting cases we have encountered in our professional work are car rugs and mats. More precisely, the use of 3D scanners in the dimensional control process by manufacturers of this type of product.
As it turns out, this industry, closely related to the automotive industry, is struggling with the problems of the above-mentioned nature. What has been neglected so far, the control of the dimensions of mats and rugs and the storage of dies, along with the geometrically growing number of car models slowly causes what can be called "choking". While the processing capacity is and will continue to be, the storage of dies and the control of the manufactured goods begins to burden the rapidly growing companies in this segment.
Our research and development team decided to try to solve this problem, reaching for devices and software that have already been tested. In this case, we hired an excellent 3D scanner from THOR3D called Calibry, as well as widely available and popular software for CAD / CAM design.
Calibry 3D scanner
Calibry is a lightweight, small-sized 3D scanner that is designed to scan medium to large objects (from 20 cm to 10 m). The Calibry 3D scanner has a resolution of up to 0.6mm, has a built-in camera and can store up to 3 million points per second.
The Calibry 3D scanner is a professional, innovative work tool of the highest quality. A redesigned camera with color recognition capability delivers unmatched high quality results. The built-in touch screen ensures high scanning comfort in any working environment. Advanced software, available in Polish, will allow you to process the obtained scans in an intuitive way.
The software we used in this case was ABViewer and AutoDesk Netfabb.
Scanning and digitizing process
The Calibry scanner can work and collect data in three modes, i.e. by the characteristics of the object, markers, and texture, thanks to which our research team had quite a lot of activities to consider. After several attempts to scan in each of these modes, we came to the conclusion that in this case, the fastest and most effective scan will be using markers. Due to the fact that the assumption of objects will be more than one or even ten, we decided to create a kind of scanning substrate to which we attached markers. Thanks to this treatment, a large variety of shapes and sizes of mats and rugs did not pose any problems for us. Working with a workplace prepared in such a way significantly accelerates and improves the digitization process itself.
At this point, you should also focus on the software with which the scanner itself works - i.e. Calibry Nest, which, apart from visualization and simple scan editing functions, has many other interesting tools that allow for intermediate work with the scanned object. A skilled operator of the Calibra scanner and Nest software is able, thanks to the implemented tools, to make simple measurements of scans, which at this stage can be used as a reference material in the control of product dimensions with a pattern or a punch.
The digitized model of a mat or rug, or a die pattern, can be saved as an element of the product library and returned to it at a later time, using it in the quality control process.
After scanning and digitizing objects, we can use a wide range of software that allows us to carry out measurements and calculations of interest. In this "case study", however, the GLOBAL3D R&D team identified two programs as promising with good forecasts for solving the problem. They are Abviewer from Cadsofttools and Netfabb from AutoDesk.
Abviewer is a universal software for working with drawings. It allows you to preview, edit, convert, measure and print CAD files of DWG and other types as well as 3D models and raster images. It allows you to work with image fragments as well as groups of files. The program allows you to compare the content of files, print and also has an API. In addition to the above-mentioned features, this program allows you to dimension three-dimensional objects saved in the .STL format and save the results in the form of a report generated by the software or dimensioned projections of objects to PDF and other files.
Netfabb is a tool for preparing models for printing. G-code for 3D printers can be generated on the basis of models saved in STL format. Netfabb allows you to view models (also in the form of a mesh), and at the same time automatically fixes various imperfections that may adversely affect the quality of the printout, such as incomplete surfaces or intersecting solids. This program also has interesting options for dimensioning objects saved in the STL format, thanks to which we are able to generate a dimensioned projection of the object we are interested in. It can also easily calculate angular lengths and radii of circles, which is quite important in the case of objects that contain rounded surfaces.
3. GOM Inspect
GOM Inspect is a free 3D inspection and mesh processing software for dimensional analysis of 3D point clouds, as well as a viewer of data sets obtained from the application.
The process of using the Calibra 3D scanner and widely available software presented in this case study allows for an effective and fairly quick (after gaining practice) way to perform an analytical control of the dimensions of car mats and mats. These types of applications can of course be extended to virtually any industry. It can also be treated as an introduction to reverse engineering in creating / restoring objects. However, please remember that this is not a ready-made solution that can be transferred one-to-one to every problem. It is rather a signpost of how it can be done.
We encourage you to familiarize yourself with the GLOBAL 3D offer on our website www.global3d.pl and in other media. We will be happy to help you solve your problem.