An Introduction to 3D Scanning for Additive Manufacturing
An introductory guide on how 3D scanning can enable easier additive manufacturing with rapid and accurate digitization of physical objects.
Additive manufacturing, also known as 3D printing, allows the creation of 3D objects from digital files. To leverage the full power of this additive manufacturing process requires first having an accurate digital model of the physical object you wish to replicate or modify.
3D scanning delivers a rapid, cost-effective method for digitizing physical objects down to precise surface details. It captures dimensions and surfaces without any contact or damage to the item being scanned. This 3D scan data can then be used like any other digital 3D model file for visualization, analysis or additive manufacturing using 3D printing methods.
This transformational capability allows you to “reverse engineer” existing objects for duplication, modification or digital archival without having to rely on building measurements and CAD drawings from scratch. 3D scanning delivers a faster and more accurate replication process of even the most complex product geometries.
Ready to gain an advantage by adding affordable 3D scanning hardware and software to enable your additive manufacturing initiatives? This beginner’s guide will get you started understanding this technology.
Table of contents
· Why Use 3D Scanning for Additive Manufacturing?
· How Does the 3D Scanning Process Work?
· Overview of 3D Scanning Techniques and Methods
· Putting 3D Scans to Work for Additive Manufacturing
· Key Takeaways for Leveraging 3D Scans
Why Use 3D Scanning for Additive Manufacturing?
Additive manufacturing promises a digital method of object fabrication, but physical inputs are still needed in the creation process. Using 3D scanning technology delivers key advantages:
- Speed– Get accurate digital files from free 3D scanning in minutesinstead of hours of physical measurements
- Cost– Reduce expenditure through fast scanning to files versus new product design costs
- Accuracy– Complex measurements converted to high resolution mesh filesfor precision prints
- No Damage– Non-destructive scanning preserves condition and uses of existing objects during digitization
With these upgrade performance benefits for additive manufacturing workflows, integrating affordable scanning tools is an easy choice. All source objects are scanned without harm for reuse after digitization — only their digital twins get manipulated or reproduced in downline processes via accessible 3D printable file formats.
How Does the 3D Scanning Process Work?
3D scanning most often relies on lasers or other optical scanning technology to fully capture physical object dimensions in the form of digital data files without any physical contact. Key phases include:
- Scanner emits scanning element such as a laser stripe towards object
- Scanner sensor detects the size, shape and sometimes even color data reflected back
- Software processes these scans into a full 3 dimensional digital mesh recreating the surfaces
- Mesh post-processing creates the final model formatted for downstream 3D printing or visualization uses
Various modes of 3D scanner equipment with different approaches toward collecting coordinate measurements exist, but the core scanning process follows those 4 essential steps in some form to digitize objects accurately.
The resulting digital file enables further design work including model repair, editing, ready-to-print conversions or even parametric builds based off the captured source. This delivers extensive flexibility for your additive manufacturing methods once you have scanned your object’s mesh source data.
Overview of 3D Scanning Techniques and Methods
Various approaches and types of 3D scanning hardware have emerged leveraging common technologies adapted for real-world applications. Each method comes with its own pros and cons targeting specific uses which dictate scanner type selections.
We will briefly introduce the most common 3D scanning mechanism categories here since scanner hardware technology affects feature sets. Selecting your method for a use case usually becomes one of your first considerations when adding 3D scanning capacity:
- Laser triangulation– A laser dot or line is projected onto the scanned surface and specialized cameras calculate depth based on the displacement of the laser. Delivers detailed scan data for smaller object sizes.
- Structured light– Projects a pattern of dots, lines or grids and senses distortions with cameras to capture details. Accommodates medium to large objects with high resolution results.
- Photogrammetry– Processes 2D photographic image capture patterns from a variety of angles to reconstruct full 3D models through software. More manual process allowing large object scanning. Can leverage smartphone cameras in some cases.
- Contact basedmethods — Uses a mechanical probe to make physical contact recording precise point locations across measured surfaces. Resolved high accuracy tradeoff requires longer scan times.
Additional specialized scanners leverage X-Rays, sonars or other sensing methods for niche applications from metrology inspections up to self driving vehicle depth mapping. But those introduced form the bulk of accessible scanners used currently with photogrammetry, laser or structured light delivering a mix of affordability, ease of use and multi-purpose scanning capabilities.
Putting 3D Scans to Work for Additive Manufacturing
So how do these digitized replicas from 3D scans convert to downstream printing or additive manufacturing uses? The last step involved processing completed 3D scan data sets through mesh manipulation stages:
- Mesh file export– The 3D scanner software finalizes a closed triangulated model saved out to an STL or OBJ file format readable by 3D printers
- (Optional) Mesh repair– Third party software can scan mesh files to auto repair errors that could cause print failures
- Slicer import– Mesh file gets positioned properly then imported to printer slicer software like Cura for final additive manufacturing prep
- Part printing begins– With the build environment calibrated, the data drives the physical nozzle and bed motions to recreate the scanned object
This scanning digital twin Handoff to 3D printer workflow enables you to deliver durable plastic or resin printed parts matching your original object’s designs in customizable materials. Sections being replicated requiring strength or flexibility allow adjusting prints for alternate plastic filaments or tweaked infill patterns not possible from originals.
Access to affordable, easy-to-use scanning gear or services now provides on-demand conversion of objects to digital for additive manufacturing reuse. Driving production via these scans sidesteps lead times otherwise required when having to create extensive CAD models from scratch.
Key Takeaways for Leveraging 3D Scans
- Additive manufacturing depends on having accurate digital source model files to deliver finished prints — 3D scanning hardware effectively bridges physical objects to printable data
- Various technologies from laser scanning to photogrammetry offer accessible and automated ways to digitize objects down to precise surface details without damaging them
- Completed 3D scans get refined into high resolution mesh models then positioned in slicers to enable additive printing
- Finished prints maintain original objects’ accurate dimensions but enable alternate material choices or custom configurations impossible with non-digital fabrication
Want to kickstart integrating affordable on-site 3D scanning into current product designs or downstream print production? Reach out for personal advisory covering best practices tailored for your use case requirements.
Start here to build out an additive manufacturing rapid prototyping advantage with 3D scans capturing existing parts ready for your next innovative iteration!
This post is originally published at 3dprintjunction.com
We thank everybody who has been supporting our work and requests you check out 3dprintjunction.com for more such articles
