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3D
Scanning has myriad essential applications in the world we live. 3D Scanning is a key initial technology in the
process of 3D Fabrication as it enables key 3D data to be referenced prior to
CAD Modeling in the course of both new product development and the development
of modifications to existing structures & product. 3D
Scanning then enables 3D data post development in quality &
compliance processes.
It is most common for us to
visualize 3D data in “space” via a 3D grid system. From a “Zero” datum (a fixed
point from which all data can be referenced), we can project outwards an X,Y,Z
measurement model. X is lengthways, Y is width, Z is height. Most of humanity’s
great structures throughout time feature a combination of horizontal and
vertical elements, these structures will have required forethought &
spacial planning and will have utilized a similar system. Without a fixed or
otherwise referenced datum/s, 3D data can have no control or meaning.
3D Scanning is performed and the
outcome is 3D file datapoints. This file can be saved, edited and even
recreated in physical form using 3D printers.
Importantly, the data output is “point cloud” which is
non-geometric. Point cloud data is basically “as scanned” surface data,
converted to a mesh or polygon based surface. This data is non-geometric and
useful reference as is, however in many product development applications it
will be imported into 3D Modeling software and used to facilitate correctly
engineered, geometric surface data.
3D Scanning was first developed in the latter half of the last century as a means to recreate, in 3D data,
surfaces of objects & places in order to facilitate developments & improvements. The concept of mapping datum points in space is fairly simple. The methods by which to generate this data and the accuracy of that output however, has seen significant development since.
This development has embraced multiple new technological developments over time. Early approaches looked at physical “touch” to generate data or a combination of lights, cameras and projectors. While broadly successful, these systems required great effort & time.
Technological developments continued apace in the years to come. The 1980’s witnessed the introduction of lasers, which have become the predominant technology to date. Optical technology became the preferred model for 2 primary reasons; Touch scanners, which are still in use today, are limited by reach of touch & are problematic in respect of soft or fragile surfaces. Optical technology has greater range, can capture immense amounts of data in just seconds and enables capture of additional elements like color & graphics (Referred to as “Texture”).
Of the optical data collection methods, “stripe” excelled in data capture and remains in use today. Stripe technology passes over a surface using multiple points of reference to measure surface area from. Accurate, rapid levels of data capture result. A continuing area of development relates to the fact that lasers see only what they can reflect from a single viewpoint. Laser light, of course, can’t turn corners.
For this reason it’s been necessary to scan any 3D object from multiple viewpoints in order to fully capture a 3D form. Subsequent scans must be accurately matched (a process referred to as “registration”), to create a complete, integrated file comprising multiple scans. In recent years development focus has been multi-layered; software and computing power enables data collection from multiple viewpoints, including the use of drones. Registration is no longer a manual process. AI is
being introduced to 3D Scanning to enable the process to become both fully automated & increasingly user friendly.
3D Scanning is integral to the process of 3D
fabrication. Designers, engineers & various technical roles utilize this
technology for useful 3D spacial reference in the course of developing new 3D
developments. 3D Scanning will continue to
play an increasing role in the fields of Quality Control, Scanning of hand
sculpted designs, Scanning of biological non geometric forms including the
human body as well as myriad other applications. It is now the case that even
mobile devices such as cell phones and digital cameras are beginning to offer
scanning capabilities to consumers.
Besides applications listed below, all of these industries
utilize 3D Scanning for the purposes of 3D
Modeling.
Automotive 3D Scanning to constantly update surface changes
in 1:1 clay models for comparison to existing digital engineering & design
files.
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Aeronautics |
Multiple applications |
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Architects |
3D |
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Medical |
3D |
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Dental |
3D |
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Jewelry Making |
3D Scanning |
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Video Gaming |
3D Scanning |
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Special Effects & Animation |
3D Scanning Location & Environment for Virtual Camera 3D Scanning of static 3D |
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Reverse Engineering |
3D |
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Quality Control |
3D |
Quality Control 3D Scanning is routinely used in pursuit of quality control. 3D Scanning can rapidly assess conformity in both
new product production & in-service equipment, whereby scans are created of
3D surfaces and efficiently compared to digital “master” data. Where errors in
surface, beyond specified tolerance exist, scanning becomes an invaluable
quality control tool.
3D Scanning has evolved a number of successful formats, each suited to a variety of applications:
Scan accuracy varies considerably
between technologies, and higher accuracy comes at a higher cost. The subject
to be scanned, the scanning environment & the resolution and accuracy
required of a 3D Scan output file will
contribute to a determination of which technologies present the best solution
for the task. Besides the accuracy between measured points and their actual
location, scanners also vary in terms of resolution, which is the distance
between captured points at a given scanning distance. This means details on the
scanned object that are smaller than the scanner’s resolution won’t be
captured.
3D
Scanning technologies vary greatly in respect of area that a scanner can
successfully capture.
Desktop scanners are suited to
smaller objects. Handheld scanners can be manually moved around the subject and
have fewer size constraints than desktop models. Handheld scanners, depending
upon cost, have much greater range, can scan instantaneously and can capture
precise measurements. Handheld scanners are ideally suited to taking human
measurements (where the subject is not perfectly still) for ergonomics and
medical applications. Some scanners utilize a single axis turntable from which
to rotate the subject. For further accuracy, some scanners have the ability to
move the subject around multiple axes, capturing scan data from multiple
angles. This feature can be a requirement for complex objects with deep
recesses whereby scan data captured from multiple angles becomes an imperative.
If an area of the model can’t be seen by the scanner it will cause a void, or
occlusion, in the scan data. These issues are easily repaired within most
scanning software however these patches are rarely accurate to the physical
surface properties.
Projects involving a larger scope
will often be addressed by Laser Pulse (Time-of-Flight/Lidar) 3D Scanning.
Precision can be adjusted per application, however, very high resolution
and quality settings generate very large 3D Scanning files.
A single laser beam is projected onto
a surface & the change in the trajectory of the projected laser beam is
recorded by a sensor.
This data is combined with a
distance reading (of the scanner to surface) and, via trigonomic triangulation,
a continuous data file of the surface may be recorded.
The change in trajectory of the laser beam combined with
the distance from surface position of the sensor is calculated via trigonomic
triangulation formula which, combined with the position of the scanner enables
continuous mapping of the surface to a 3D scanning
data file.
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Advantages |
Laser Triangulation 3D Scanning enables high
resolution & accuracy. Accuracy in the range of 0.1 mm or better is
possible. |
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Limitations |
Laser Triangulation 3D Scanning laser beams are at times sensitive to shiny &
transparent surfaces. |
Structured
Light 3D Scanning measures the pattern of
light deformation upon a surface. Light is projected in linear patterns onto a
surface and the scanner analyses the edge of each line as it makes contact.
This data is combined with a distance reading (of the scanner to surface) and,
via trigonomic triangulation, a continuous data file of the surface may be
recorded.
Structured light is generally white or blue, is generated
via the use of Digital Light Processing (or similar) projectors and is either a
series pattern or dot matrix.
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Advantages |
Structured Light 3D Scanning
enables both high resolution & speed and is effective for Human Body
Scans. Structured light can achieve higher accuracy than laser
scanning due to the noise caused by laser speckle patterns. In general, structured light scanning
provides the best resolution and accuracy, typically slightly higher than
laser scanning. |
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Limitations |
Structured Light
3D Scanning is sensitive to
lighting conditions and is difficult to use effectively outdoors. |
As
the name suggests, this technology records multiple photographs of a static
subject from multiple angles then, via computational geometry algorithms and
computer vision, the photographs of the subject are reconstructed into a 3D
form. Parameters including focal length and lens distortion are required, then
pixels in corresponding images are automatically detected from which an
accurate 3D model is be created. Under ideal conditions, object detail captured
by photogrammetry can rival a laser scanner, however, geometric accuracy is
usually worse due to the lack of fixed reference points for the camera’s
position.
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Advantages |
Photogrammetry 3D Scanning will reconstruct large or small
subjects photographed from the ground or the air with precision. |
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Limitations |
Photogrammetry 3D Scanning requires significant computing power
to process multiple images and to cross reference pixels within each to
create 3D data. The system is sensitive to image resolution and algorithmic
processing can be time consuming. |
Touch
sensor scanning involves either a moveable probe attached to a measuring device
capable of spanning a desired area while recording its position in space.
Conversely, a static probe with a moveable object can be employed. As the probe
makes contact with the subject deformation triggers point recognition. 3D data
is built up over time until a complete picture is generated. CMM’s (Coordinated
Measuring Machines) fall into this category of scanners.
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Advantages |
Touch Sensor 3D
Scanning (Digitizing) is precise and effective upon both reflective
& transparent surfaces. |
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Limitations |
Touch Sensor 3D
Scanning (Digitizing) is problematic in respect of soft, deformable
surfaces and is time consuming. |
Laser
Pulse 3D Scanning relies upon the travel time of a Laser from source, to
subject, then reflected back to a sensor, to calculate the geometric contours
of a surface. The speed of light is a known unit of measure and so by measuring
the interval time between the emission and the reflected return of a laser beam
to the scanner, accurate measurements can be generated.
The
scanner will employ a single laser, firing laser pulses on a pico-second
(0.000000001 seconds) frequency. The laser pulses are reflected from a rotating
mirror mounted upon a 360’ rotating scanner unit. The resulting array of laser
pulses reflect a single data point each from the environment and a
comprehensive 3D data file is the result.
Precision can be adjusted per application, however, very
high resolution and quality settings generate very large 3D Scanning files.
|
Advantages |
Laser Pulse 3D
Scanning (Time-of-Flight / Lidar)
is accurate & suited to large scale scanning applications. |
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Limitations |
Laser Pulse 3D
Scanning (Time-of-Flight / Lidar)
laser beams are at times sensitive to shiny & transparent surfaces. |
3D
Scanning is a comparatively new capability of mobile phones.
Increasingly, 3D Scanning features will be
fully integral features, per the Xperia XZ1.
Currently, it is more common to download a 3D
Scanning App such as 123D Catch from Autodesk or Kinect from Microsoft.
Having decided upon an App, directions are simple; Select the subject, be sure
that access around the subject is uninterrupted and that lighting conditions
are even throughout. Initiate the scanning procedure, 3D
Scanning all facets around the object while maintaining a constant
distance between the phone and the subject. 3D Scanning
sensors within the phone then collect & process data. The output
file may be exported to a wide number of applications from use as an Avatar in
a Virtual Reality environment or game, through to 3D Printing.
Touch sensor 3D Scanning (Digitizing),
captures very manageable amounts of data, however, Laser & Light based 3D Scanning systems capture very large amounts of
data per file. For many projects, multiple scans from a number of viewpoints
will be required resulting in multiple, large & related files. If multiple
related files are collected, they will first be aligned via “registration”, one
to the other, to form a complete 3D picture. These combined scans will then be
optimized by deleting excess data and then “repaired” (dependent upon
application) by filling holes etc. Ultimately, the file can be exported into a
number of standardized file formats including PLY, OBJ, STL, ASC, FBX. for
downstream use.
Some 3D
Scanners have fully integrated post-processing capabilities however,
additional advanced post-processing software may be required for other industry
applications including reverse engineering and quality inspection. Due to the
large size of the files created, powerful computing capability saves valuable
time. It is also possible to combine data output from a variety of types of
scanners into a single output file.
It is important to capture high
quality raw data during the acquisition stage because post processing will
typically clean data and reduce file size, reducing overall resolution and
quality. The offset here is that high quality resolution at the data acquisition
stage is potentially very time consuming. An experienced technician, aware of
the resolution ultimately required by the client, will be knowledgeable and
experienced in the compromise required between time spent in data acquisition,
and the required quality of the end product.
3D
Scanning will see continued growth in coming years as both industry
& consumer demand continues to increase.
Allied Market Research report in
September 2018, that the global 3D Scanning
market was valued at $8,427.0 million in 2017, and is projected to reach
$53,345.0 million by 2025, registering a Compound Annual Growth Rate (CAGR) of
25.7% from 2018 to 2025. North America was the highest contributor to the
global market, with 39% of the market share in 2017, registering a CAGR of
23.1% during the forecast period 2018-2025.
Allied Market Research September 2018
Markets & Markets report in July
2017, that the 3D Scanning market is
expected to grow from USD 3.76 billion in 2017 to USD 5.90 billion by 2023, at
a CAGR of 7.8% during the forecast period. The market growth can be attributed
to the increasing need to capture large volumes of 3D data for modeling and
analysis, rising focus on quality control, and growing awareness about advanced
medical treatments.
Markets & Markets July 2017
This data refers to 3D Scanning
Market by:
• Type
(Optical Scanner, Laser Scanner, and Structured Light Scanner),
• Range
(Short Range Scanner, Medium Range Scanner, and Long Range Scanner),
• Service
(Reverse Engineering, Quality Inspection, Rapid Prototyping, and Face Body
Scanning), and
• Application
(Entertainment & Media, Aerospace & Defense, Healthcare, Civil & Architecture,
Industrial Manufacturing, and Others)
Key 3D
Scanning developers include: Faro Technologies, Inc., Creaform, Inc.,
Direct Dimensions, Inc., GOM mbH, Konica Minolta, Inc., 3D Digital Corporation,
Autodesk, Inc., 3D Systems, Inc.
The above reports into the future of 3D Scanning identified the following key
considerations in respect of future growth:
5. 3D Scanning is playing an integral role in
shortening product development and manufacturing times by streamlining the
QA/QC process.
6. Ongoing
technological advancements concerning portability, scanning range & image
quality are opening new application areas for this equipment.
7. Increasing
demand in the 3D Printing market, high definition content recording for movies
and historical site preservation by 3D Scanners are
some of the factors that are expected to create lucrative growth opportunities
during the forecast period.
8. 3D Scanners that use any combination of laser
triangulation, phase shifting, time-of-flight technologies are expected to hold
the largest share of the market, due to ease of use and wide availability.
9. The
portable coordinate
measuring machine (CMM) segment of the 3D
Scanner market, which includes handheld and articulated arm CMMs—is
expected to grow at the highest CAGR during the forecast period. Not
surprising, given the versatility of portable CMMs, which enable users to scan
tight spaces with high accuracy.
10. The close
relationship between 3D Printing and 3D Scanning means
that growth in the former market is likely to spur growth in the latter as
well. Moreover, 3D Scanning applications far
outstrip those of 3D Printing, at least for the foreseeable future.
11. Most 3D Scanners remain expensive, a major restraint
toward the adoption of these scanners.
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