Solution

Case Study: As-Built Modeling of Powered Parachutes

Project Overview

The project requirement was about 3D scanning two powered parachutes to be integrated into Microsoft Flight Simulator. For achieving an accurate representation (geometry and texture), sophisticated reality capture technology stacks were prioritized.
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Client Overview

The client for the project was an American aircraft manufacturer based in Hastings, Michigan, specializing in the design and production of powered parachutes. This initiative aimed to provide Microsoft’s Flight Simulator users with an authentic experience of flying these unique aircraft.

Project Highlights

  • 2 powered parachutes were scanned with precision as the top-most priority.
  • Laser and handheld scanning were combined for dual application.
  • A 3D model was created for integration with flight simulators.
  • Mesh model development and texturing were done seamlessly.
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Process & Execution

The laser scanning process

The laser scanning process utilized the Leica RTC360 laser scanner, probably the best in the market. RTC360 helped in accurately capturing the overall dimensions and geometry of the facility. In parallel to that, the Artec Leo scanner was used to record surface details for the enhancement in facility geometric data acquired.

Point cloud to mesh conversion

Then, the point cloud data was generated and hence processed subsequently using cloud processing to mesh model software workflow. The objective was to create a mesh model with accurate textures, further to be worked on.

Mesh model to 3D models

Finally, the mesh models were processed to be proper 3D models as the digital replicas of real-world aircraft. Then models were reviewed for integration into Microsoft’s Flight Simulator.

Challenges

  • The laser scanning process: The laser scanning process utilized the Leica RTC360 laser scanner, probably the best in the market. RTC360 helped in accurately capturing the overall dimensions and geometry of the facility. In parallel to that, the Artec Leo scanner was used to record surface details for the enhancement in facility geometric data acquired.
  • Point cloud to mesh conversion: Then, the point cloud data was generated and hence processed subsequently using cloud processing to mesh model software workflow. The objective was to create a mesh model with accurate textures, further to be worked on.
  • Mesh model to 3D models: Finally, the mesh models were processed to be proper 3D models as the digital replicas of real-world aircraft. Then models were reviewed for integration into Microsoft’s Flight Simulator.
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Arrival 3D industrial Scanning

Solutions
How the Result Was Achieved

  • Complex Aircraft Geometry: Acquiring high-density point cloud data for accurate and thorough analysis of the motorized parachutes’ complex construction and lightweight frame was one big challenge.
  • Texture Accuracy: Several high-resolution images and point cloud data were required to be captured and mapped, respectively, onto the model.
  • Data Processing Complexity: A vast amount of scanned data was to be processed, and therefore, specialized software was utilized for effective point cloud data processing.
  • Environmental Constraints: Due to distortions and reflections, the scanning had to be done in a controlled environment.

Results & Benefits

  • Precise and accurate 3D models: Detailed and well-textured as-built 3D models for Microsoft’s Flight Simulator to integrate with ease.
  • Time and Cost Savings: The design-to-digital workflow was streamlined by doing away with the requirement for hand modeling.
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Highlights

Project Gallery

Solution

Key Insight

This particular project defines the importance of utilizing the right set of laser scanning technologies to achieve the desirable project outcome. The usage of RTC360 and Artec plus intelligent point cloud to model conversion software resulted in precise data processing, and therefore, realistic digital replication

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