The Quality Cycle in a Precision 3D Scanning Process

With the proliferation of 3D scanning technologies, many options are

available for obtaining an electronic 3D file of a scanned object. The quality
of results varieswidely. Of those that have experienced poor results, some
complain about the accuracy of the data. Others have voiced concern over
the usability of a completed file, having found that it does not work for their
particular application.

In a recent poll, 57% of respondents that had used

scanning said they received “successful” results less
than 80% of the time. A full 21% said that success was
achieved less than half the time. While this
information may be shocking to some, it is no surprise
to others. It has become all-too-common for first-time
users of 3D scanning services to find themselves
shopping for a better solution or, worse yet,
discouraged from using scanning services again.

What is shocking is that such low levels of quality exist in a process that is
quite critical to the product development and manufacturing cycle. Scanning
technologies are used at the very beginning of product development for
capturing reference geometry. Then again in the product validation phase to
compare first production samples to the new CAD model. And finally as a
problem solving tool to improve tooling performance or product reliability.
Quality results of less than 80% would not be tolerated in any other part of
the product development/manufacturing cycle. Yet this level of quality is
commonplace with scanning services.

Without exploring all of the potential reasons why,one thing is very clear.
Whether it’s laser scanning, white light scanning, CT, or another 3D scanning
process, even fundamental disciplines of quality are little-used with a
technology that has come of age.

As a customer of 3D scanning services, one would

become well-informed about the quality of the
service that will be provided by inquiring about the
service with regard to the 4 steps in the Deming
cycle. Asking questions and supplying the critical
information associated with the Plan, Do, Check, Act
improvement cycle will dramatically increase the
success rate of a 3D scanning output. Most scanning
operations are first-time events, so use of the
Deming cycle becomes a prevention tool before the
first scan is performed.
 Planning is perhaps the most critical stage in the reverse
engineering process. It’s also the point at which many errors are
made.

The first step in the plan is to define what you expect to do with the output
from the scan. What will be the next step? That is, what will you do with the
file in the very next sequence of your process?

Once the next step is defined, how do you see the file being used in the
future? Will it be edited at some point? The answers to these questions will
help define what type of file needs to be developed from the scan. You may
be using the file to compare the part to your existing CAD as a first article
inspection method. That expectation requires one output of a file. Your goal
may be to perform an FEA (Finite Element Analysis) on the object. That will
require another type of file. Perhaps you need to offset a feature from the
surface of the part; that will require yet another type of file to produce a
successful result. Define the next step and future use of the file very clearly
before any scanning work begins.

Second, work with an engineering team that not only has complex modeling
expertise, but understands the product development cycle and precision
manufacturing in general. This depth of knowledge is indispensible in
producing a robust file that can be put to use quickly.

Third, clarify what surface preparation may need to take place to obtain an
accurate point cloud. Most precision parts require some sort of surface
preparation before laser scanning or white-light scanning can begin.
Scanning technology has improved dramatically in recent years such that
less preparation is necessary. Even so, to achieve the best positional
accuracy from the scan, the surface should be flat (non-reflective), opaque
(non-transparent), and white.

The ideal surface to scan is an eggshell. Unfortunately, few eggs require

laser scanning. Therefore, some preparation is usually required to replicate a
non-reflective, non-transparent, white surface. If the part can be painted, one
of the best prep materials is a flat white spray paint. This adds .0002" -
.0004" of thickness to the surface when properly applied. Paint is best used
on metal parts such as castings that can be cleaned with a paint remover, or
on parts that are disposable.

A more common prep material is developing powder used for die-penetrant

inspections. It adds .0005" - .0010" of thickness to the surface and can be
washed off with soap and water.
Perhaps the project is too precise to add a layer of paint or powder to the
surface. Some parts can be made less reflective by glass bead-blasting. A
negligible amount of material is removed from the object while the surface
layer is "disturbed" slightly to reduce reflectivity.

If none of these options are possible, a combination of scanning (for

reference) and precision dimensional inspection can be employed.

Proper surface preparation is a critical step in the scanning process.

Fourth, confirm the level of accuracy you'll be provided. Know what error is
inherent in the prep & scanning process and how much error may be
introduced by the surfacing/modeling steps. The sum of these two will be a
good estimate of the overall error to expect in the finished file.

The second step, “DO” is the implementation of each of the

decisions and adjustments that were made during the plan. What’s
most critical here is that a robust quality system is in place and
followed in the development of the scanned point cloud and
resultant CAD file.

The system must include a bullet-proof method of translating the

communications that took place during the planning stage to the
technician/engineer performing the work. How does the information
exchanged during the quote process develop into a clear set of work
instructions? Perhaps this is an obvious step. Yet in a process such as
scanning where every project has a unique set of requirements, this point of
information exchange holds one of the highest potentials of error. A process
of continuous improvement is indispensible in this area. As a user of
scanning services, ask the question, “how are your project details translated
into work instructions”?

Another important component in this second step of the Deming cycle is that
there is thorough training to validate skill sets for the individuals performing
the scanning and modeling processes. The training should also include
actual industry experience. Not only experiencein scanning and modeling
components from different industries, but hands-on manufacturing and
designing work experience in a variety of industries. This will bring a depth
of understanding to the completion of the file you will need for your project.

Checking is all about analyzing the data on the solution. Data

analysis begins with verifying that the point cloud came from a
quality scan. This includes evaluating stray points and checking to
ensure there was no unplanned movement during the scanning
cycle. In this image, a clean scan is compared to an invalid scan where scan
layers do not match with one another.
During the CAD file construction, analyzing the
data repeatedly is an integral part of the reverse
engineering process.

Multiple color
comparisons
such as the one
shown here will ensure that all features are present,
constructed to the correct size, and that they are in
proper position. A complicated component may
require more than one hundred color-compare
checks before the file is ready for final inspection.

The final inspection should be accomplished with a second set of eyes. Preferably
by someone else that has manufacturing or tooling experience associated with the
product under review. This final check must be a full review of the plan that began
when the project was initially quoted.

Be well informed about how your provider performs the check step throughout the
build of your model.

Now the project is ready for presentation to the end user/customer. This live
demonstration of the finished file at completion is a final check with the intent of
helping the customer understand what decisions were incorporated into the
designand the process that was used to build the model tree. Sometimes
corrections or adjustments come out of this review that need to be acted upon.

A good reverse engineering process integrates a loop of checking and

acting until the final electronic file meets the intended use. The last
“Act” step is the adoption of the final solution; putting closure on the
project, and including any additional adjustments the customer may
need. Perhaps more importantly, this is an opportunity to identify systemic
changes that can be implemented to standardize the solution. That way all
future projects benefit from those changes.

As a user, be sure you will be afforded the opportunity to review a live

presentation of your reverse-engineered result. This way you’ll have an
opportunity to identify those items that need to be acted on before final
delivery. Discuss the incremental improvement process your provider uses
to ensure the highest quality scan results.

The continuous improvement quality cycle as an integral part of a robust

reverse engineering process.
David DeVowe
The QC Group, Inc.
www.theQCgroup.com