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LET'S TALK ABOUT 3D SCANNING

Reverse Engineering a Jeep Wrangler 2005 Auxiliary Light Bracket Mount with 3D Scanning

7/23/2024

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THE PROBLEM: The Jeep Wrangler auxiliary light bracket mount had a stress fracture thus needed to be replaced.

THE CHALLENGE: Reverse Engineer the Jeep Wrangler auxiliary light bracket mount and make it stronger than the original bracket mount using the latest 3D scanning and 3D printing technologies.
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.
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3D scan of the bracket
3D scan STL file
jeep_bracket.stl
File Size: 52799 kb
File Type: stl
Download File

Step 2: Reverse Engineering

We required expert knowledge rather than simply converting the 3D scan data into a solid model in CAD as the output was going to use additive manufacturing technology, and 3D printed metal. Therefore Growshapes worked with an expert at Uniformity Labs to create the output required. Groweshapes sent the raw scan data in .stl file format to Marlon. Marlon, who led Application Engineering at Uniformity Labs started the reverse engineering process by importing the .stl file of the original design that Growhapes 3D scanned into his CAD software Solidworks.  For Marlon, extracting the geometry data from scan data was easier and required less time than measuring the bracket with calipers as it gave accurate values quickly. Furthermore in the CAD software, Marlon was able to model directly over the scan using it as a constant reference. The key expertise Marlon added further was optimizing the design for additive manufacturing in metal, i.e. removing as much material as possible while ensuring strengths which results in adding lattice design.  
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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. 
​
See the full additive manufacturing workflow​ below:
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Courtesy of Uniformity Labs
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.
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Growshapes the official U.S. distributor of Shining 3D EinScan 3D scanners. We now carry the eviXscan 3D scanner and THREE from Matter and Form as well!

​See the innovators on Growshapes’ social media channels to get the latest expert news on innovation in 3D digitization, then share your thoughts and join the conversation about 3D digital innovation with #digitize3D
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3D Scanning and Reverse Engineering Project: Efoil Wing

7/2/2024

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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.
PART I: 3D SCANNNING TO CAPTURE THE ACCURATE SIZE AND CURVATURE
Step 1: Preparing for 3D Scanning
​
Before diving into the scanning process, you'll need the right tools and a suitable environment.  Here is what we used.
  • EinScan Pro HD 3D Scanner
    • This scanner is suitable for mid to large objects, thus was chosen to scan the efoil wing.  For smaller objects, we would recommend the EinScan Pro 2X V2.
    • This scanner captures black and shiny surfaces well too without having to spray its surface.  Also can capture intricate details but in the case of the foil wing, there were none.
    • It save digital files in STL, OBJ, ASC, PLY, P3, 3MF file formats.  For details about the file formats, read the blog here.
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EinScan Pro HD and the Wing prepared with markers
  • Markers
    • 3mm reflective markers that come with the EinScan Pro HD.
    • Placed markers in a random, non-linear pattern. 
    • While scanning, we made sure at least 4 markers in each frame were captured.
Step 2: 3D Scanning the Efoil Wing​
  • Calibrated the EinScan Pro HD according to the instructions provided on the screen.  This is very simple.
  • Placed the efoil wing on a stable surface in a room with consistent lighting.
  • Scanned the wing in Handheld Rapid Scan mode with Hybrid Alginment using both features and markers. Usually, the tracking is lost when there are not many features, thus starting from where there are a lot of features so the 3D scanner.  I started from the middle top part then went right and left.  Also if you hold the EinScan Pro HD at a 45 degree against the surface you are trying to capture, it works better. Also on the EinScan Pro series software, you can check the scan quality as you scan so you can tell what quality of scan you are capturing.
  • Once I had scanned one side of the wing, saved it as a project group.  Then flipped the wing over, scan the other side similarly, and saved it as a separate project group.

​Step 3: Post Processing 
  • Cleaned up each scan and point cloud data for each project (delete floating parts etc)
  • Aligned the 2 scans using manual alignment. Due to the thinness of the wing, the automatic alignment was slightly off.
  • Generated a mesh model using the mesh optimization parameters which will remove spikes, fill marker holes etc.
  • Cleaned up the mesh (used the advanced features available in the post-processing stage such as deleting floating parts, filling holes, reducing file size etc) then saved as .stl.
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Aligning the Front & Back Scans
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Post-Processed 3D Scan Mesh File
Here is the STL file so you can further reverse engineer and manufacture via 3D printing!
wing_aligned.stl
File Size: 40403 kb
File Type: stl
Download File

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!

​See the innovators on Growshapes’ social media channels to get the latest expert news on innovation in 3D digitization, then share your thoughts and join the conversation about 3D digital innovation with #digitize3D
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Ditch the calipers and use a 3D scanner for reverse engineering!

2/8/2023

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Edward Van Zyl, a seasoned 3D scanning and printing expert from Manitoba, heads the company Dreamworks 3D Printing and Scanning. With extensive expertise in vintage car restoration and customization, he is enthusiastic about utilizing state-of-the-art equipment to capture intricate details of automotive components and then utilizing software to generate accurate 3D models. This article, courtesy of Shining 3D, deep dives into the tips utilized by Edward for scanning with the EinScan HX Hybrid Light Source Handheld 3D Scanner and the reverse engineering of car parts through the use of Geomagic Essentials and Fusion 360.

Scanning And Printing An Arrow 50 Scooter Part

Edward embarked on a projet to 3D scan and reverse engineer an Arrow 50 scooter part and then 3D print. He chose the EinScan HX Hybrid Light Source Handheld 3D Scanner for this reverse engineering project.

In the 3D scanning process, Edward provides a small tip: utilizing miniature pyramids as markers rather than some of the markers that need to be put directly onto the object. This has the advantage of saving time and cost, as it eliminates the need for post-scan cleaning and the small pyramids can be reused. You may download files of pyramids here.
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Arrow 50 Scooter Part & Pyramid Markers Photo: Courtesy of Shining 3D
In laser scan mode, EinScan HX has a maximum scan speed of 480,000points/s. It just took around 12 minutes to complete the whole scan of the component. And the laser scan mode of EinScan HX makes the scanned data accurate up to 0.04mm, thus you get a very accurate model for subsequent work.
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Scan File generated by EinScan HX Photo: Courtesy of Shining 3D
Below is the 3D printed part from Bambu Lab X1-Carbon Combo 3D Printer.
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3D Printed Part Photo: Courtesy of Shining 3D
Cutting A Fender Using Geomagic Essentials

Edward’s goal was to cut a fender and make sure it was the right size for installation. Usually, he will print out the part for test, and in this case he offers an easy-to-print and material-saving trick.

​He creates a small offset about 5 mm or even less, and cuts the part again, so that he gets a tiny piece of the fender, but maintains the geometry he need. 3D printing this thin piece was just as good for installation testing, and using only a minimal amount of printed material.
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Cutting the fender in Geomagic Essentials Photo: Courtesy of Shining 3D
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Small Offset of Fender in Geomagic Essential Photo: Courtesy of Shining 3D
Reverse Engineering An Engine Using Geomagic Essentials And Fusion 360

Furthermore, Edward uses Geomagic Essentials to extract features on the engine, and then using Fusion 360 to model the three holes in which he wants to simulate the mounting bolts.
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Extracting features in Geomagic Essentials Photo: Courtesy of Shining 3D
One thing to keep in mind here is that you need to maintain the mesh and the extracted features in uniform coordinates. This step ensures that the extracted features can be overlayed on the mesh in the right position. After extruding two cylinders of different sizes and modeling some threads, the mounting bolt is done.
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Modeled Mounting Bolts and Brackets Photo: Courtesy of Shining 3D
This is basically how to go from scanning to printing of a part; how to use a mesh and model mounting bolts in Geomagic Essentials and Fusion 360. And it is clear how much can be done with a bundle of 3D scanners and softwares.


You may find more operation details in the playback video. If you found this content useful, please follow Shining 3D's webinar pages, so you won’t miss out on more information.

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

​See the innovators on Growshapes’ social media channels to get the latest expert news on innovation in 3D digitization, then share your thoughts and join the conversation about 3D digital innovation with #digitize3D
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Reverse Engineering with 3D Scanners

2/2/2023

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Are you still using calipers? Have you tried reverse engineering using 3D scanners? It's a new tool for an old task.

Merriam-Webster defines reverse engineering as "the process of disassembling and examining a product or device to discover the concepts involved in its manufacture, usually with the goal of producing something similar."

As the design process is beoming digitized, reverse engineering today is more commonly associated with the process of converting a physical object’s geometry into a digital 3D model and replicating the original design or further improving for new manufacturing processes such as additive manufacturing. More engineers are moving away from using calipers and adopting 3D scanners to take measurements, especially of complex parts.
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Reverse Engineering Model, Courtesy of Shining 3D

3D scanners allows you to digitally capture the geometry of even the most complex parts in an extraordinarily quick and precise manner. A large docking pump was recently captured in just 20 minutes for example, with the help of laser 3D scanning. This technology has enabled the use of reverse engineering in situations beyond simple benchmarking and part reproduction, as we explore in the next section.

Main Applications for 3D Scanning & Reverse Engineering

Reverse engineering with 3D scanning offers many possibilities for product development and manufacturing. Overall, the different uses of reverse engineering can be divided into three major applications: (1) to replicate parts,  (2) to create variations of existing parts, or (3) to develop entirely new parts based on an existing environment or object. Let's look at each application in a bit more detail.

1. Recreate & Replicate Parts

One of the most popular uses for 3D scanners is recreating damaged or worn-out parts that are unavailable from the original supplier or lack proper documentation. This is a common problem when working with old machinery or vintage vehicles, and it’s always challenging to do with manual reverse engineering tools like calipers. However, with a good 3D scanner and the proper software, it can become a straightforward task.

Katsuya Tanabiki, for example, shared his process of reverse engineering a shield notch on an old motorcycle helmet. The helmet featured two shield notches, but one was broken, and it was too difficult to obtain a replacement notch. This tiny part was 3D scanned with an EinScan Pro 2X in Fixed Mode, and later 3D printed.
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Photo: Courtesy of Shining 3D
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Photo: Courtesy of Shining 3D
Sometimes the actual fabrication of the part is not the end goal. In aerospace and automotive industries reverse engineering is adopted to digitize components and create digital inventories of legacy parts. These digitized components are known as “digital twins”.

In generating a "digital twin', 3D scanning is indispensable to capture the intricate details of the parts with strict dimensional requirements to meet the required standards. Take for example, 
this small turbine reverse-engineered by Print3DD. The distinguishing geometry of its blades would be impossible to reproduce accurately without 3D scanning.
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Small Turbine Photo: Courtesy of Shining 3D
2.  Improve The Design of Existing Parts
​

Another goal of reverse engineering is to use digitized parts to create new and improved variants instead of merely reproducing them. This method can significantly reduce the time and costs of creating parts from scratch and also ensures a perfect fit for components belonging to larger assemblies.

Taiwanese company Kiden Design has illustrated the reverse engineering process of optimizing a pipe using 3D scanning, CAD, and 3D printing. The EinScan Pro HD 3D scanner, used in Handheld mode, captured the irregular geometry of the pipe on two opposite sides that were stitched together later in software.  Thanks to the accurate 3D model obtained, the geometry could be easily optimized in CAD.
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Optimizing the Pipe Design Photo: Courtesy of Shining 3D
Another good example of reverse engineering being used to create new versions of a physical objects is the customization of furniture parts with 3D scanning and CNC wood carving by Voxel 3D. In this project, the carved ornaments of one piece of furniture were digitized with 3D scanning and integrated into different parts.
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3.  Create & Design Entirely New Parts

Another application for reverse engineering is where a part is digitized as a reference to create entirely new parts. This procedure is usually employed when a tight fit is required on an existing part that is too complex or has an irregular interface.
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Kick Panel Design Process, Courtesy of Shining 3D
To illustrate this, let’s look at a use case from the Fuller Moto automotive customization shop. Bryan Fuller and his team used the EinScan Pro 2X Plus to 3D scan the entire footwell of a 1967 Lincoln Continental. The digitized region was used as a reference to design a new kick panel, and the precise 3D model of the footwell made it possible for the new part to fit flawlessly in the customized car.

​This particular technique is also commonly practiced by medical professionals since body parts are unique and challenging to accurately replicate using manual methods. Here, 3D scanning once again has proven to be an efficient tool for digitizing human parts and surfaces.

Earmolds, for example, are patient-specific parts that help conduct sound from the hearing aids to the ear canal. Servicing or creating new earmolds from scratch can take several weeks during which patients experience hearing problems without them. However, thanks to reverse engineering methods with 3D scanning and 3D printing, the Hearing Beyond Audiology Clinic in Toronto can produce temporary earmolds in just one day. The temporary accessory allows patients to keep their hearing while waiting for the earmolds to be produced or serviced in other facilities.  Similar reverse engineering methods with 3D scanning are also utilized for producing facial prosthetics and custom orthotics.
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Earmolds Photo: Courtesy of Shining 3D

Quality Data Capture Is Key for Successful Reverse Engineeing

​The use cases above clearly demonstrate the central role of 3D scanning in reverse engineering. It comes as no surprise that the effectiveness and accuracy of data captured by 3D scanning are crucial for a successful reverse engineering process. Yet, the software tools used for processing the data and working with the 3D models are also essential for achieving the desired results in reverse engineering. To understand the importance of good data and adequate software, let’s go over the main steps of reverse engineering with 3D scanning.
Step 1. Data acquisition

The very first step in any reverse engineering process is data acquisition. Regardless of the method, proper planning and preparation can make the difference between good and poor data. With 3D scanning, this involves selecting the correct device for the job, including the proper configuration (handheld or stationary) and accessories such as turntables, fixtures, and calibration panels. Correct calibration of the device is also vital to acquire quality data.

The regions or parts to be digitized usually demand some kind of preparation. Besides a good cleaning, some 3D scanning devices also require the use of markers or even special coatings on reflective surfaces. One should also consider the ambient conditions before starting the digitization process. A controlled environment (e.g. indoors, without direct sunlight, a cleared tabletop, …) is always preferred to reduce noise in the data, but that’s not always possible. All the factors mentioned will contribute to proper data collection, which will in turn determine how quickly and easily the data can be processed next.

Step 2.  Post-Processing

The next step in a reverse engineering process is post-processing the acquired data, or the  “point cloud”. Here, the point cloud is processed by software tools – like EinScan software – resulting in a 3D mesh representation of the digitized object.
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Point Cloud Image

In any case, the 3D model in this initial stage usually requires some refinement like removing unwanted captured data, repairing surfaces, and filling gaps per below.
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3D mesh data editing, Courtesy of Shining 3D

​The better the data quality acquired, the less post-processing and repairing will be needed. The post-processing step is also when reference entities are assigned to the 3D model, a procedure that should expedite the next stage of the reverse engineering process.

Step 3. CAD Model Generation

The final step in a reverse engineering process is to convert the mesh representation of the physical object captured by the 3D scanner into a solid 3D model.
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CAD Model from 3D Scan Photo: Courtesy of Shining 3D

As accurate as the mesh model can be, it is inadequate for most reverse engineering applications that require additional handling like fixing any physical damage, creating variations, or designing new parts altogether. In this stage, the refined mesh model from the previous step works as an exact reference model for recreating the model using parametric CAD tools.

Although in theory any general-purpose CAD program could handle this, specially purposed software geared towards reverse engineering can make the process much easier and yield much better results too.
An appropriate CAD software for reverse engineering can also compare the digitized model to the parametric one, allowing users to check for geometrical and dimensional differences.

Conclusion

​
Reverse engineering has come a long way and 3D scanning technologies have broadened the range of industrial applications for reverse engineering, benefiting both businesses and consumers. 

The quality of the captured data is crucial to obtain good results in reverse engineering. The choice of the 3D scanning device, as well as its capabilities and functions, play a central role in the success of the entire process.  Read further about how to make sure you choose the right model for your project here.
​
Though often overlooked or underestimated, the software used in the later stages of reverse engineering also bears great importance. Specific built-in tools for the job can make a big difference in a well-executed reverse engineering process.

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

​See the innovators on Growshapes’ social media channels to get the latest expert news on innovation in 3D digitization, then share your thoughts and join the conversation about 3D digital innovation with #digitize3D
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New updates for Solid Edge Shining 3D Editions 2022

5/9/2022

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Solid Edge 2021 brought us powerful performance updates to make our working flow more efficient in the areas of Reverse Engineering as well as Part Modeling, and this year, it moves further, launching the promising and practical next generation design functions, Subdivision Modeling and Convergent Modeling.
Let´s take a look at the detailed updates of Solid Edge 2022 and discover its advantages and innovations.

Please note:
  1. Users who activated Solid Edge SHINING 3D Edition Floating Version (not for dongle key) between 2021/5/9 and 2022/5/9 can update to the latest version for FREE. Download the software now.
  2. Users who activated Solid Edge SHINING 3D Edition before 2021/4/26 can obtain a FREE license in exchange for a Solid Edge/EinScan case study. (See reference@https://youtu.be/QhN5jqbbEiI) If you are interested in updating via this option, please fill in the form.
  3. For more upgrade options, please feel free to contact [email protected]

Subdivision Modeling Enhancements

Subdivision Modeling makes it easier to generate a stylized body and control its shape by using a polygonal cage. Solid Edge 2022 introduces new modification functions.
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Bridge

In the Subdivision Modeling environment, you can use the new "Bridge" command to create a loft-like feature that connects edges or faces selected on a single cage or two separate cages.
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Open bridge, with edges as input
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Two section bridge, with shape curve
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No shape curve, linear bridge
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One-sided bridge

Offset Cage Faces


Offset allows users to select faces of a cage and offset them along their normal direction. Offset allows users to select faces of a cage and offset them along their normal direction. Offset allows users to select faces of a cage and offset them along their normal direction
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​Split with Offset
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Allows adding local detail to model without having to split the entire model, use the new "Split with Offset" command to add detail to a face by offsetting the new faces inward by a user-defined amount.
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​Align to Curve
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​Use the new Align to Curve  command to fit the vertices of body cage faces to one or more existing curves or to curves you interactively sketch. You can undo and redo each curve edit until you achieve the desired shape.
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​Convergent Modeling

Solid Edge now supports mixed mesh modelling (a.k.a Hybrid Convergent modelling). Mesh and Classical faces are in one body, this is extremely helpful when you do assembly reverse engineering and 3D printing.
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The new "Show Facet Edges" command controls the display of facet edges within a model. When selected, the command displays the facets; when deselected, the facet edges are not displayed.
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​Reference Point Cloud

New capability to insert .asc point cloud scan files into Assembly. Visualize & evaluate Solid Edge models in the context of point clouds
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​With all new features, Solid Edge 2022 Shining 3D Edition allows you to do more with your scanned data.  It is the practical and efficient solution for engineers, designers and 3D enthusiasts for sure.

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

​See the innovators on Growshapes’ social media channels to get the latest expert news on innovation in 3D digitization, then share your thoughts and join the conversation about 3D digital innovation with #digitize3D
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Reverse Engineering the 1973 Mini Cooper steering column cover parts with EinScan Pro 2X

4/21/2022

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Challenge: Finding replacement parts for a classic car
John Buffington is a classic car enthusiast. He loves restoring cars to their original glory and breathing new life into a classical design.  He recently noticed that many of the interior plastic parts of his beloved 1973 Mini Cooper was succumbing to the hot temperatures and high UV exposure of the Nevada desert. One of the critical interior pieces that required immediate replacement was the two steering column covers. The covers were dry, brittle and decaying.  They needed to be replaced as they were no longer able to be secured together. However, with a rare classic car like this 1973 Mini Cooper, finding replacement parts in the US is extremely difficult and expensive.
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The 1973 Mini Cooper
Solution: EinScan Pro 2X fills the gap
​John, also being a talented engineer and with his deep knowledge of 3D printing technology, he decided to reverse engineer these Mini Cooper steering column covers and 3D print new replacement parts. Rather than measuring the parts with a caliper and designing in CAD from scratch, John decided to 3D scan the plastic steering column covers to generate a 3D digital surface model to get accurate measurements of the parts with the EinScan Pro 2X 3D scanner​
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He used the EinScan Pro 2X 3D scanner with the Industrial Kit, which is the tripod and automated turntable accessory that enables higher accuracy scanning in fixed mode. When using the Industrial Kit, the handheld 3D scanner is placed on top of the tripod and converted into a desktop 3D scanner and used in conjunction with the automated turntable.  This set up automates the whole 3D scanning process as well and enables a more precise alignment utilizing the markers on the turntable. 

​The black steering column plastic parts were covered with AESUB spray to ensure every detail was captured.  The AESUB spray lightly coats the object with a thin layer of white powder which evaporates automatically after use without leaving any white residue, making the whole process cleaner.  The EinScan Pro 2X captured the dimensions of the object with exceptional precision and accuracy, picking up every minute details, giving John the confidence to reverse engineer the steering column covers.  The details of the screw bosses that would have been difficult to measure by calipers were captured by the 3D scanner. The EinScan Pro 3D scanner was simple to use and provided more accuracy than manual measurement. Instead of having to design from scratch, John was able to to create high quality 3D surface mesh files using the 3D scanner.
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The EinScan Pro 2X 3D scanner with the Industrial Kit enabled John to put the object on the turntable and within an hour or so, get a workable 3D mesh. Multiple scans were automatically fused together to create a watertight 360-degree digital surface mesh that was then imported into the Solid Edge Shining 3D Edition reverse engineering software. The surface mesh files were leveraged to build a solid model, make design improvements, and then be further process for 3D printing.
Results: Capturing details enabled precise CAD file creation for 3D printing 
​By using the EinScan Pro 2X, John was able to capture the surface details of the steering column covers as a mesh file (.stl format) which he then imported into the Solid Edge Shining 3D Edition CAD software in which he converted the .stl file into a  .step file with precise details of the fastening features, the alignment pins and screw bosses. 

Time-consuming, inaccurate, and inconsistent manual measurements are now a thing of the past and with 3D digital technology, reverse engineering a classic car part can be fast and accurate.
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“By using the 3D scanner, I was able to focus on creating the CAD file suitable for 3D printing without having to wrestle with measurements and generating a CAD file from scratch.”  - John Buffington.​

Also importatnt to note is to understand copyright laws in the US.  Reverse engineering is legal but if you are going to reproduce and profit, you should get in touch with a patent lawyer. With an old part like above, it's beyond the copyright

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

​See the innovators on Growshapes’ social media channels to get the latest expert news on innovation in 3D digitization, then share your thoughts and join the conversation about 3D digital innovation with #digitize3D
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EinScan 3D Scanner File Types 101

3/15/2022

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3D scanner is a data-acquiring device that captures the surface model of a physical object in a digital polygonal model. The types of output data format that 3D scanners can generate maybe confusing. What is an ASC file? Which export formats does my CAD software import for rapid prototyping? What is the best practice for saving scans? Which file format is the best choice for 3D printing?  In this post, we will discuss all file types that involve Einscan software.

The type of file you require depends on what you are going to do after the scanning process. There are a total of 6 types of output data formats (ASC, p3, STL, PLY, OBJ, 3MF) that you can export from EinScan software during data capture and generating mesh which are polygon models. We will explain the differences among these 6 file types in this blog.

Point Cloud Data Format

When you have finished your scan and are ready to convert your raw scan data to point cloud data, you can click on the save button to save the point cloud data as an ASC file and the marker position as p3 format when markers are detected.

ASC file contains the position information of each point in the point cloud. This file type can be opened in most scan data processing software and metrology software like Meshmixer, GOM Inspect, and Geomagic Essentials.

The P3 file is for marker reuse purposes in EinScan software. For a large object scan, the user can scan all markers only first and save the marker frame as a p3 file. Later the object can be scanned part by part in a separate project using the same p3 file as a reference which improves the accuracy and will require no alignment between each project.
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With Fix scan mode number of scans will be saved as separate files, while for handheld scans the full point cloud will be saved as one file.

Meshed Data File Format

After the data is meshed, more saving options will be available. ASC file is still available while the mesh can be saved as STL, PLY, OBJ, or 3MF files.

STL file format is the most common mesh file format. It only contains the position and normal directions of all triangles in the mesh. This polygon file format can be opened by mesh editing software and many CAD software like Solid Edge or Solidworks for reverse engineering.

PLY and OBJ file formats contain mesh texture information, including color information, in addition to the STL file. Users can export these data types for digital documentation and online model display.

3MF file is the 3D printing format published by the 3MF Consortium. This format includes information about materials, colors, and other information that cannot be represented in the STL format. Windows system and other CAD software packages can open this mesh format.
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Post Processing Data
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EinScan software provides basic functions for mesh editing in Post Processing and Measurement sections. Usually, users use these functions right after meshing data. However, external mesh data can also be imported into the EinScan software for editing. The EinScan software supports STL, OBJ, and PLY formats for post-processing and measurement.
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Saving Data in Project Group

The 3D scan data in the EinScan software are saved for later use in a two-layer structure. When the user starts a new scan,  a new project group is created. All the associated files in the project group will be saved as a project under a folder named by the project group.
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The project group folder contains different kinds of files. The project group directory links all projects in the group. The project directory links all data files belonging to this project and the rest are project data files. When moving the project group, the user needs to move all the folders in the project group. 

When opening the project, the user needs to locate the folder where the project group was saved and open the corresponding directory files.The project group folder contains different file formats. The project group directory links all projects in the group. The project directory links all data files belonging to this project and the rest are project data files. When moving the project group, the user needs to move all the folders in the project group. 

When opening the project, the user must locate the folder where the project group was saved and open the corresponding directory files.
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So that's it!  You have 6 output formats to choose from and all the required scans for your saved project will be in a project group folder.  Remember, the file size for each project is large, so make sure you secure a space on your PC where you can save the files.

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

​See the innovators on Growshapes’ social media channels to get the latest expert news on innovation in 3D digitization, then share your thoughts and join the conversation about 3D digital innovation with #digitize3D
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Reverse engineering, 3D printing and helping lives

3/17/2020

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3D Printed Valves. Photo courtesy of dezeen.
Recently the media picked up a story about how 3D printing saved the day to produce valves for an intensive care unit in Italy to treat COVID-19 patients.  The Italian startup company reverse engineered, and 3D printed these valves that are key components of Venturi oxygen masks that are connected to ventilators.  

When you read the details however, you realize they jumped various legal hurdles to do this - the valve is protected by copyright and patents with its blueprint not released but in an emergency case such as this one, the hospital seemed to have allowed them to reverse engineer the valve and 3D print them.  The CEO of the company that 3D printed the valves is now is explaining what his intentions were on his Facebook post and LinkedIn video (in Italian).

When emergencies of such enormous scale occur as is happening right in front of our eyes, you just want to help if you have the capability and technology to solve the problem quickly. But regulations exist to ensure safety and durability thus everybody in the 3D printing industry is doing a thoughtful balancing act. 

It is not clear if they used a 3D scanner or just used calipers to do the reverse engineering but 3D scanners can play a key role in enabling accurate and quick reverse engineering of physical objects.

Using 3D scanning technology, you can capture the surface dimensions of complex physical objects accurately and quickly especially with the structured light 3D scanners, then then reverse engineer with various CAD software such as Geomagic and Solid Edge which comes bundled with EinScan Pro 2X & 2X Plus to create a blueprint that can be 3D printed. 

Have a look at how you can reverse engineer products that are missing a blueprint by using 3D scanners.
https://www.growshapes.com/einscan-pro-2x-3d-scanner-series-bundle.html
​

Growshapes is an HP Silver Partner of HP 3D scanning solutions and the official U.S. distributor of Shining 3D EinScan 3D scanners. We are now carrying the eviXscan 3D scanner from Evatronix too!

​See the innovators on Growshapes’ social media channels to get the latest expert news on innovation in 3D digitization, then share your thoughts and join the conversation about 3D digital innovation with #digitize3D.
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Receive a free Color Pack add-on with the purchase of the EinScan RED (Reverse Engineering Design) Bundle

11/1/2019

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Starting today until December 20, 2019 you will receive 1 free Color Pack accessory when you buy the complete EinScan Reverse Engineering Design (RED) Bundle for the EinScan Pro 2X or EinScan Pro 2X Plus.

SHINING 3D’s RED bundle is the premier solution for scan to 3D design workflows as it features both Geomagic Essentials by 3D systems and Solid Edge SHINING 3D Edition by Siemens PLM software.

Complete reverse engineering has never been easier than with the EinScan RED bundle. Geomagic Essentials is the ideal solution for scan to print and downstream reverse engineering applications as it extracts all the necessary elements of a scanned part for immediate use in CAD software programs. This functionality allows for an easy transition into Solid Edge SHINING 3D Edition. With the convenient and powerful CAD tools provided by Solid Edge, you can complete reverse engineering, generative design, and simulation to achieve your creative ideas.

Read more here.

BuY THE RED BUNDLE

​The complete RED Bundle with this special promotion includes:
  • EinScan Pro 2X / 2X Plus Multi-functional Handheld 3D Scanner
  • Industrial Pack Add-on (Turntable and Tripod)
  • Solid Edge SHINING 3D Edition
  • Geomagic Essentials, available exclusively for SHINING 3D
  • Color Pack Add-on (Texture Camera) November 1st through December 20th
​​​
There has never been a more complete package for 3D scan to design workflows!

Growshapes is an HP Silver Partner of HP 3D scanning solutions and the official U.S. distributor of Open Technologies 3D Scanners and Shining 3D EinScan 3D scanners.

​See the innovators on Growshapes’ social media channels to get the latest expert news on innovation in 3D digitization, then share your thoughts and join the conversation about 3D digital innovation with #digitize3D
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