3D Scanning, Reverse Engineering, and Data Capture

Overview

  • TEAM provides a range of optical scanning technologies, including handheld and benchtop scanning solutions. 
  • We offer reverse engineering services for instances where parts are no longer commercially available, or a new design must be derived from an existing object.
  • We also feature the requisite hardware and software to execute motion capture, and gait analysis projects. 

3D Scanning

3D Scanning can be used to create a digital 3D representation of an existing physical object at an accuracy of ~50-100 microns. The digital models can be used for graphic visualization, reverse engineering, replication, and designing surrounding parts or assemblies.

Output

Our typical output file format is 3D mesh STL. This dataset is a 3D mesh made up of points in space, connected by lines to form triangles. If you desire a Parametric model derived from the scan data, we can assist with this procedure as well (at additional cost).  Examples of parametric model formats include Solidworks, Autodesk Inventor, or STEP file formats.

vehicle door
Objects As large as a vehicle can be captured via handheld scanner
scandata
Small objects can also be captured at fine detail
TEAM hardware

The team lab is armed with an assortment of different types of 3D scanners (handheld, and bench-top).  We are able to capture data in-lab, or on-site.

picture of handheld 3D scanner
Einscan Pro2X Handheld Scanner
Benchtop 3D Scanner
Nextengine Benchtop 3D Scanner
Revopoint Miraco Handheld Scanner
Revopoint Miraco 3D Scanner

Pros:

  • Handheld
  • High Definition

Pros:

  • Scanning-stage automates data-capture process 
  • Highest Definition
  • Good at processing small objects with fine details

Pros:

  • Handheld
  • Extremely Compact
  • Intuitive

Cons:

  • Necessitates computer to manage and store incoming data (provided by TEAM).
  • May struggle to capture small objects

Cons:

  • Slow compared to other scanning solutions

Cons:

  • Self-Contained
  • Lower scanning resolution than other solutions
  • May struggle to capture small objects
Example Scan Data
3D Scan of ear
3D Scan of an ear video

 

 

Scanner Compatibility

Generally, our 3D scanners work by emitting structured light (visible, or non-visible) and studying the reflected light that bounces back.  As such, objects are ideally opaque, with no hidden/interior features in order to capture a clean-scan.  In instances where your object is translucent or reflective, we can apply a temporary spray coating (which evaporates off after a few hours) to make your part compatible with our process.  

NOTE: These scenarios may present challenges for optical 3D scanning:

  • Glossy, or metallic surfaces, or red-colored objects – light tends to reflect off of these surfaces, making them challenging for the optical scanners. One potential work-around would be to temporarily clad the object in a temporary coating that is more amenable to scanning (coating naturally evaporates off after several hours).
  • “Soft” objects, that distort while being moved, or living objects – if the object changes shape, or moves during scanning, the scanner’s software may struggle to stitch multiple angles together.
  • Objects with internal features, or deeply recessed features 
Ideal Scale

Ideal objects for 3D scanning range from a minimum of a few centimeters in length to a maximum size roughly equivalent to an automobile.


Reverse Engineering

Often related to, or incorporating elements of 3D scanning, our reverse engineering service utilizes skilled engineers to develop parametric models from existing physical parts. This process is particularly valuable when replacement parts are no longer commercially available or when new designs must be derived from or replace existing objects. We provide accurate digital models to support redesign, modification, or replication efforts.

Digital Calipers

Note

  • With decades of engineering design expertise, we approach reverse-engineered models with the same mindset as the original engineer, ensuring that our models faithfully reflect the original design intent

Data Capture: Motion Capture & Gait Analysis

TEAM is equipped to perform motion capture and gait analysis. We recommend using iPi Soft Motion Capture software with two Microsoft Kinect 2 sensors, which can be enhanced by adding additional cameras for improved capabilities.

TEAM Hardware and Software

Our motion-capture system uses two Microsoft Kinect2 sensors, webcams, and scene reconstruction/analysis software. These tools primarily capture an object’s geometry or analyze gait and movement. The Kinect2 sensors employ an array of technologies, including time-of-flight sensors and cameras, to gather data.


Rates

  • Note: We strongly recommend submitting a service request to obtain an accurate project cost estimate. Self-quoting can often lead to miscalculations

Our development services come with a simple per-hour rate defined in the chart below.  We assess a 1 hour minimum, then to the nearest quarter hour.  If your process involves use of our 3D scanning technologies, we also access an hourly fee for use.

 DescriptionInternalExternal
Professional Engineer Development TimeDesign time, machine setup, etc.$119/hour$160/hour
Student Development Time*Design time, machine setup, etc.$30/hour$40/hour
Scanner UseHourly rate for machine use$6/hour$8/hour

*Student development time may not be available, or applicable to all projects.  The TEAM lab will leverage it where possible.

Estimating project cost should be left to TEAM, but here are some general project estimates that can guide in self-estimating:

Relative Project ScaleDevelopment HoursDevelopment Expenses*, **
Simple Scan, No Mesh Repair1 Hours$30-$119
Simple Scan, Simple Mesh Repair1.5-3 Hours$100-$150
Scan with Mesh Repair3-5 Hours$150-350
Scan with Advanced Mesh Repair or Augmentation5+ Hours$350+

*All declared values at internal rates, NUD = university required "Non-University Differential" added for external.

 


 

Get Started

  • Heard enough? Get started with a service request!  Your request need-not be perfect, we can always revise it as we go. Just provide us with as much detail as is necessary.

Begin a service request now

  • Feeling overwhelmed with the options?  We don't blame you!  We do a lot!  Feel free to email us to set up a consultation.  We're happy to chat via zoom, or in person (where we can review samples).