3d solid laser modeling

3D SOLID LASER MODELING

Manufacturing Automation

December 8th, 2010

Presented By: Christopher N. Berry

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)

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.

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

Laser Scanner Mechanics

Data Acquisition

Data from laser transmitted to computer via USB.

Able to manipulate scan parameters. Resolution Quality

Laser Beam Pitch

Rotation Angle

Object Height

Object Reconstruction

Side View Top View

Data Conversion

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

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

Post Processing

Used to eliminate scanning errors

Increases accuracy of scan

Enables reconstructed object to be utilized in CAE platform.

Post Processing Phase 1:

Importing Scans into SolidWorks

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

Open File as “Mesh”Step 2 of 14

View Mesh of PartStep 3 of 14

Select “Mesh Prep Wizard”Step 4 of 14

Select the Mesh you Wish to ProcessStep 5 of 14

Select “No Orientation”Step 6 of 14

Use Tools to Select and Delete Excess MaterialStep 7 of 14

Hand Select Excess Material and RemoveStep 8 of 14

Simplify Mesh SizeStep 9 of 14

Change Global SmoothnessStep 10 of 14

Increase Boundary SmoothnessStep 11 of 14

Before After

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

Fill Model Holes (Post-Implementation)

Create Model SurfaceStep 13 of 14

Delete Surface ErrorsStep 14 of 14

Finalized Surface Model

Post Processing Phase 2:

Post Processing in SolidWorks

Object is Broken Into Mesh Sections

Enable Mold Toolbar

Create Surface from Hole Edges

Pre-Fill Surface Technique

Pre-Fill Surface Application

Fill Surface Application

Pre-Fill Surface Application

Pre-Fill Surface Application

Pre-Fill Surface Application

Fill Surface Application

Pre-Fill Surface Application

Fill Surface Application

Finalize Desired Surface Fills

Perform Digital Render

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.

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.

Questions?