LET'S TALK ABOUT 3D SCANNING

1. Background

Chris loves driving around Lake Tahoe in his open-top Jeep Wrangler, enjoying the blue skies and fresh air. The Jeep Wrangler is his vehicle of choice for fun adventures and transporting his wet dog after a swim in the lake. One day, Chris noticed that one of the auxiliary light mount brackets at the front had cracked. Initially, he planned to search for replacement parts, but then he heard about Growshapes' 3D scanning technology. Intrigued by the idea of reverse engineering and 3D printing the bracket, he contacted Growshapes to explore the possibilities. The original bracket mounts were made of plastic and had cracked under stress, so Chris was looking for a solution that would be stronger and more durable than the originals.

​2. The Tools and Method

Growshapes used Einscan Pro 2X 2020 to 3D scan the cracked plastic bracket mount and worked with an engineer at Uniformity Labs to reverse engineer and create a metal 3D-printed replica.

3. The Reverse Engineering Process

Step 1: 3D scan the bracket mount to capture complex geometries using Einscan Pro 2X 2020

Growshapes received the broken plastic bracket mount from Chris. Judging from the size of the part, we decided the best scanning tool was the EinScan Pro 2X 2020 that can capture intricate details with high accuracy, especially in fixed scan mode using it in conjunction with the automated turntable.  For small objects, EinScan Pro 2X is the way to go for sure.  It captures fine details as point cloud data, then converts it into a mesh that can be exported as an .stl file into a CAD software such as Solidworks. 

Growshapes 3D scanned the black plastic part that had a fracture on the main wall of the bracket mount. You can see the fracture in the scan results below.  We scanned the bracket in fixed mode to digitally capture accurate data of this small part.  Fixed scan mode was chosen to use the 3D scanner with the automated turntable. There was no need to put any markers on the parts as the scan was aligned to the markers on the turntable and didn’t even require spraying even though the part was black. The Einscan Pro 2X 2020 uses structured white light technology and the software allows for the capture of dark parts.

The steps that were taken from editing the scan files to  print:

1. The scan was imported into CAD software as points and surfaces
2. Measurements were collected and construction geometry such as planes, contours, etc. were extracted from the scan data
3. The bracket was modeled from this reference geometry generated by the scanned data
4. That design was then "optimized" for additive manufacturing, removing as much material as possible, adding lattices
5. The optimized design was exported from CAD as an STL file
6. The STL file was sliced in Netfabb using the latest EBPA
7. The SLM 125 (for AlSi10Mg) and SLM 280 (for 316L) were prepared and the prints launched
8. The builds were removed from the machine, cut off of the build plate, and sonicated
9. Supports were removed by hand

Some of the challenges Marlon faced specifically for optimizing for additive manufacturing:

• Required other software beyond just the CAD software. Other software, such as nTopology, simplifies modeling more organic shapes conducive to additive manufacturing
• Limited information about the end use of the bracket (how much it was going to support, environmental conditions, etc thus had to make assumptions

Things specifically engineered to optimize for 3D printing:

• Material removal for light weighting
• Lattices for additional stiffness
• Kept overhangs to 45 degrees to minimize support and post-processing
• Made assumptions regarding loading and boundary conditions

The original bracket was made from injection molded plastic but the plastic gave way to stress over time. The metal bracket should be stronger than the original plastic bracket mounts.  Marlon decided to use 316L (stainless steel) as is resistant to corrosion in harsh weather and can withstand varying temperatures. Injection molding requires a substantial investment in tooling thus requires volume production but with additive manufacturing, one-off print is possible with drastically shorter lead times. 
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See the full additive manufacturing workflow​ below:

Chris is happy with the new and improved auxiliary light bracket mount that is stronger than the original one that came with the Jeep Wrangler.  He won't have to worry about having another stress fracture in the bracket mount.  Reverse Engineering is not just about replicating but also about improving upon the original design!  

Check out the mounting brackets that were fixed onto the Jeep Wrangler below.

In the ever-evolving world of watersports, efoiling has taken the spotlight with its thrilling combination of surfing and flying above water. Efoil boards, propelled by electric motors, offer an exhilarating experience, and at the heart of their performance lies the efoil wing. However, this industry is young and manufacturers struggle to survive such as FOIL Inc (getfoil.com)  as there is not enough demand out there leaving enthusiasts in a lurch when their favorite wing model is no longer available to purchase and the original designs may be lost. Fortunately, 3D scanning and reverse engineering offer a lifeline for reviving these designs. In this blog post, we'll explore how you can use 3D scanning technology to bring an out-of-production foil wing back to life.

Importance of the Efoil Wing

The efoil wing is crucial for the lift and stability of the board, directly affecting the rider's experience. Each wing model has its unique design that caters to different riding styles, water conditions, and skill levels. When a beloved wing is no longer produced, finding a suitable replacement can be challenging, making reverse engineering an appealing solution.  We have 3D scanned the efoil wing 200 of the FOIL series using the EinScan Pro HD with high accuracy as the initial step to enable full reverse engineering and manufacturing.

Here is the STL file so you can further reverse engineer and manufacture via 3D printing!

PART II: REVERSE ENGINEERING
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1. Import the 3D scan into the reverse engineering software/CAD software of your choice - such as SolidWorks, Fusion360, or Quicksurface. Analyze the model's dimensions, curves, and features. Understanding the wing's design characteristics is crucial for accurate replication.
2. Using the CAD software, recreate the wing's design. This step may involve tweaking the original design to improve performance or adapt it to new materials. Ensure that the redesign maintains the key features that made the original wing perform well.
3. Simulation and Testing: Before moving to production, use simulation tools within the CAD software to test the wing's performance. Simulating the wing's behavior in various conditions can highlight potential issues and areas for improvement.

PART III: MANUFACTURING

Once satisfied with the redesigned model, it's time to manufacture the wing.

1. Material Selection: Choose materials that match or improve upon the original wing's properties. Common materials for efoil wings include carbon fiber, fiberglass, and various composite materials. FOIL was manufactured using forged carbon fiber.
2. Prototyping: Create a prototype using techniques such as CNC machining, 3D printing, or traditional molding. Prototyping allows for physical testing and fine-tuning before full-scale production.
3. Testing: Conduct rigorous tests on the prototype to ensure it meets performance expectations. This might involve real-world testing in various water conditions to validate the wing's lift, stability, and durability.

CONCLUSION
3D scanning and reverse engineering provide a powerful combination for resurrecting discontinued efoil wings. By capturing the precise geometry of a classic wing and using modern tools to refine and replicate its design, enthusiasts can continue to enjoy their favorite efoil experiences. Whether you're an efoil aficionado or a watersports innovator, this technology opens up a world of possibilities for preserving and enhancing the sport. So, don't despair about FOIL Inc going bust, let technology breathe new life into it!

​Growshapes the official U.S. distributor of Shining 3D EinScan 3D scanners. We now carry the eviXscan 3D scanner from Evatronix as well!

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