1. 3d Solid laser modeling Manufacturing Automation December 8th, 2010 Presented By: Christopher N. Berry

2. Introduction 3D Solid Laser Modeling is a modern technique used to accurately represent physical objects into the virtual world. Required Tools HD Laser (Picza3D Laser Scanner) Image Processing Technology (Dr. Picza3) CAD Software (SolidWorks)

3. 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.

4. PICZA 3D Laser Scanner Located in the Bell Hall 4th Floor IE Laboratory

5. Laser Scanner Mechanics

6. Data Acquisition Data from laser transmitted to computer via USB. Able to manipulate scan parameters. Resolution Quality Laser Beam Pitch Rotation Angle Object Height

7. Object Reconstruction Side View Top View

8. Data Conversion After reconstruction complete, save file format as “.STL”. This allows for post- processing of data in desired CAD program.

9. Post Processing Used to eliminate scanning errors Increases accuracy of scan Enables reconstructed object to be utilized in CAE platform.

10. Post Processing Phase 1:Importing Scans into SolidWorks

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

12. Open File as “Mesh” Step 2 of 14

13. View Mesh of Part Step 3 of 14

14. Select “Mesh Prep Wizard” Step 4 of 14

15. Select the Mesh you Wish to Process Step 5 of 14

16. Select “No Orientation” Step 6 of 14

17. Use Tools to Select and Delete Excess Material Step 7 of 14

18. Hand Select Excess Material and Remove Step 8 of 14

19. Simplify Mesh Size Step 9 of 14

20. Change Global Smoothness Step 10 of 14

21. Increase Boundary Smoothness Step 11 of 14 Before After

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

23. Fill Model Holes (Post-Implementation)

24. Create Model Surface Step 13 of 14

25. Delete Surface Errors Step 14 of 14

26. Finalized Surface Model

27. Post Processing Phase 2:Post Processing in SolidWorks

28. Object is Broken Into Mesh Sections

29. Enable Mold Toolbar

30. Create Surface from Hole Edges

31. Pre-Fill Surface Technique

32. Pre-Fill Surface Application

33. Fill Surface Application

34. Pre-Fill Surface Application

35. Pre-Fill Surface Application

36. Pre-Fill Surface Application

37. Fill Surface Application

38. Pre-Fill Surface Application

39. Fill Surface Application

40. Finalize Desired Surface Fills

41. Perform Digital Render

42. 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.

43. 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.

44. Questions?