3d solid laser modeling

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3D SOLID LASER MODELING Manufacturing Automation December 8 th , 2010 Presented By: Christopher N. Berry

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Page 1: 3D Solid Laser Modeling

3D SOLID LASER MODELING

Manufacturing Automation

December 8th, 2010

Presented By: Christopher N. Berry

Page 2: 3D Solid Laser Modeling

Introduction

3D Solid Laser Modeling is a modern technique used to accurately represent physical objects into the virtual world.

Required Tools

HD Laser (Picza 3D Laser Scanner)

Image Processing Technology (Dr. Picza3)

CAD Software (SolidWorks)

Page 3: 3D Solid Laser Modeling

What is Laser Modeling?

Creation of point cloud system representing a geometric surface with a laser beam.

Records distance values to the surface within the scanners field of view.

The object is then recreated in a “reconstruction” software package.

Page 4: 3D Solid Laser Modeling

PICZA 3D Laser ScannerLocated in the Bell Hall 4th Floor IE Laboratory

Page 5: 3D Solid Laser Modeling

Laser Scanner Mechanics

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Data Acquisition

Data from laser transmitted to computer via USB.

Able to manipulate scan parameters. Resolution Quality

Laser Beam Pitch

Rotation Angle

Object Height

Page 7: 3D Solid Laser Modeling

Object Reconstruction

Side View Top View

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Data Conversion

After reconstruction complete, save file format as “.STL”.

This allows for post-processing of data in desired CAD program.

Page 9: 3D Solid Laser Modeling

Post Processing

Used to eliminate scanning errors

Increases accuracy of scan

Enables reconstructed object to be utilized in CAE platform.

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Post Processing Phase 1:

Importing Scans into SolidWorks

Page 11: 3D Solid Laser Modeling

Enable SolidWorks Add-In “ScanTo3D”Step 1 of 14

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Open File as “Mesh”Step 2 of 14

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View Mesh of PartStep 3 of 14

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Select “Mesh Prep Wizard”Step 4 of 14

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Select the Mesh you Wish to ProcessStep 5 of 14

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Select “No Orientation”Step 6 of 14

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Use Tools to Select and Delete Excess MaterialStep 7 of 14

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Hand Select Excess Material and RemoveStep 8 of 14

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Simplify Mesh SizeStep 9 of 14

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Change Global SmoothnessStep 10 of 14

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Increase Boundary SmoothnessStep 11 of 14

Before After

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Fill Model Holes (Pre-Implementation)Step 12 of 14

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Fill Model Holes (Post-Implementation)

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Create Model SurfaceStep 13 of 14

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Delete Surface ErrorsStep 14 of 14

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Finalized Surface Model

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Post Processing Phase 2:

Post Processing in SolidWorks

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Object is Broken Into Mesh Sections

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Enable Mold Toolbar

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Create Surface from Hole Edges

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Pre-Fill Surface Technique

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Pre-Fill Surface Application

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Fill Surface Application

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Pre-Fill Surface Application

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Pre-Fill Surface Application

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Pre-Fill Surface Application

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Fill Surface Application

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Pre-Fill Surface Application

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Fill Surface Application

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Finalize Desired Surface Fills

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Perform Digital Render

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What are the Benefits?

Save time modeling complex components.

Accurate representation of surfaces impossible to achieve with current solid modeling technology.

Wood grains, bumpy surfaces, curves, grooves, etc.

Allows for better analysis in CAE platforms.

Motion simulation, fluid flow analysis, FEA analysis, etc.

Page 43: 3D Solid Laser Modeling

What are the Drawbacks?

High resolution scans mean large files.

Usually post processing required.

Requires high end technology

RAM RAM limits number of data points that can be created.

Processor Speed Determines how long it will take to create surface generation.

Page 44: 3D Solid Laser Modeling

Questions?