survice metrology

METROLOGY.SURVICE.COMBeyond Measure!

SURVICE METROLOGY3-D Scanning, Reverse

Engineering, Modeling,

And Inspection

SURVICE METROLOGY - BEYOND MEASURE™

OUR SERVICES 2

Providing experience

in the test and

evaluation roles that

are vital to the design,

acquisition, and

fielding of all new and

modified combat

systems.

Delivering a broad

range of modeling and

simulation, software

engineering, and

systems engineering

capabilities.

Offering customers

precision dimensional

metrology, modeling,

and related services.

Conducting a wide

variety of safety,

survivability,

effectiveness, and

systems engineering

studies.

Collecting, maintaining,

distributing, storing,

verifying, and

protecting the nation’s

critical defense

information.

Our customer-acclaimed support primarily falls into five core business areas:

TEST &

EVALUATION

MODELING &

SIMULATION/SOFTWARE

ENGINEERING

DIMENSIONAL

METROLOGY &

REVERSE ENGINEERING

STUDIES

& ANALYSIS

INFORMATION

TECHNOLOGIES

& MANAGEMENT


3SURVICE METROLOGY- ATLANTIC COAST FACILITY

SURVICE Metrology was established to be a

world-class business unit to provide integrated

metrology solutions, dimensional inspection and

modeling services, and advanced R&D capabilities

in the field of metrology.

New address… same great SURVICE!

4694 Millennium Drive, Suite 510A, Belcamp, MD

We’ve Moved!


4DIMENSIONAL METROLOGY & REVERSE ENGINEERING

• Dimensional inspection, precision alignment

• Reverse engineering

• Platform integration studies

• Sustainment / Obsolescence

• Foreign materiel exploitation

• Rapid prototyping

• Pre- and post-test damage assessment

• 3-D scanning, geometric modeling, design engineering

• Metrology integration support (manufacturing & assembly)

• Metrology tool application and development

PRODUCTS & SERVICES PROVIDED

• Obsolete part, tooling, die, mold reverse engineering,

TDPs, GD&T studies

• First Article Inspections, Physical Configuration Audits,

production part and tooling inspections

• Jig & fixture inspections / alignments

• Vehicle-to-CAD reverse engineering – ground vehicles,

aircraft, watercraft, space systems

• Hydroelectric power plant turbine inspections

• Precision alignment/inspection of C4ISR equipment

• Airplane turbine engine blade inspections

• Smithsonian museum artifact scanning and modeling

EXAMPLE PROJECTS

SURVICE offers customers

precision dimensional

metrology, modeling, and

related services, which can

be performed at a

customer’s site or at our

one-of-kind Metrology

Center.


5SURVICE METROLOGY TECHNICAL AREAS

PART TO CAD REVERSE ENGINEERING

PRECISION DIMENSIONAL INSPECTION AND ALIGNMENT



FAILURE ANALYSIS AND FORENSICS STUDIES / TEST SUPPORT



SURVICE Engineering Company Topic No. AF112-119

Phase I Interim Report #2

14

2.3 Reflectivity Analysis Under Factory Conditions

A requirement of any solution to this problem is that the photogrammetry targets must maintain a minimum of 50% of maximum reflectivity under various factory conditions, such as exposure to

oil and water. A validation of the photogrammetry technology for this effort (already conducted

by SURVICE) is the use of photogrammetry targets in an environment where surfaces may be

subjected to water and/or oil contaminants. While sensitive surfaces could have protective

covers, SURVICE understands this to be an important aspect of the proposed solution and

performed some preliminary testing. The results shown in Table 1 indicate that there is no

substantial degradation of photogrammetry targets over a range of water and oil exposure that

would affect performance, with all test results well above the minimum reflectivity needed. The

results of this research verify that the photogrammetry targets are well-suited for use in factory

conditions.

MUSEUM ARTIFACT AND ARCHITECTURAL SCANNING / MODELING / REPRODUCTIONS

CUSTOM COMPONENT 3D PRINTING OBJET 3D PRINTER


We Utilize a Variety of Measurement Systems

To Ensure the Ability to Meet Your

Requirements.

• Laser Trackers

• Digital Photogrammetry

• Portable CMM / Measurement Arms

• Laser Scanners

• Structured Light Scanners

• X-Ray Computed Tomography (XCT)

8SURVICE METROLOGY – MEASUREMENT SYSTEMS


Characteristics

Measurement

type

Individual point

or scan

Measure

components of

2 to 50+ meters

Accuracy From 25 microns

Tracked measurement target must

touch location measured

Very accurate, robust, well

proven technology.

9MEASUREMENT SYSTEMS: Faro Laser Trackers


FARO Laser Trackers

Industries and Applications

-Aerospace

-Automotive

-Precision

Engineering /

Fabrication

-Jig, fixture alignment

-Tool qualification, certification

-Tooling / line installations and

moves

-Part and assembly inspection

Power

Generation

-As-found measurements

-Alignment, final checks on install

Research /

Medical

Systems

-Particle accelerator alignments

-Proton Beam Therapy Systems

DoD/Test &

Evaluation

-Live Fire Test Setup

-Pre- and post-test measurements

10MEASUREMENT SYSTEMS – LASER TRACKERS


LASER TRACKERS ON THE JOB 11


• Large volume laser tracker, optical level, and

digital level measurement network setup and

component alignment support – 0.2-0.5mm

accuracy required over +200m spans

•Schedule – December 2012 – October 2014

• Mayo Clinic Rochester, MN – completed,

first patients treated in June 2015.

• St Jude Memphis, TN – completed

installations, commissioning facility

• Mayo Clinic Phoenix, AZ – completed

installations, commissioning facility

12LASER TRACKERS ON THE JOB


• Precision measurement support to alignment of aircraft landing arrest system

components during installation/construction phases

• Primarily using Faro Laser Trackers

13LASER TRACKERS ON THE JOB


Characteristics

Measurement type Individual points

Measure

components of

2 to 50+ meters

Accuracy 2 µm + 5 µm/m

(RMS)

3 µm + 7 µm/m

(3 Sigma)

Location measured must be

pre-targeted with reflective target

Very accurate, robust, well

proven, technology, very portable,

suitable for remote locations!

TARGETLESS PHOTOGRAMMETRY

SYSTEMS EXIST, AND WORK WELL

FOR MEASUREMENTS/MODELING

OF HIGHLY “FEATURED” OBJECTS

14MEASUREMENT SYSTEMS: AICON Photogrammetry System


15PHOTOGRAMMETRY ON THE JOB – ANTENNA STUDIES

• Sophisticated techniques for

measurements of antenna

deformations over a 24-hour period

• Portable, can make measurements

in remote areas


Characteristics

Measurement

type

Individual points

or scan

Measure

components of

0.5 to 3 meters


Accuracy drops off rapidly for parts

larger than 3 meters.

Medium accuracy, fast,

robust, well proven technology

for smaller parts, easily

portable!

16MEASUREMENTS SYSTEMS:Faro Portable Measuring Arm


17FARO ARM INSPECTION REPORT EXAMPLES


Actual Aircraft Parts Modeled Aircraft Parts

18PART-TO-CAD REVERSE ENGINEERING EXAMPLES

AGING AIRCRAFT PART / SUPPLIER OBSOLESCENCE


19TECHNICAL DATA PACKAGES


20VEHICLE-TO-CAD MODELING EXAMPLE – ABRAMS M1A2 SEP

FARO ARM DIRECT TO CAD MODELING (SOLIDWORKS, CREO, ETC.)


21AIRCRAFT REVERSE ENGINEERING & SURFACE MODELING

UAV Outer Mold Line

Engine Nacelle & Internals

Nose Landing Gear

Main Landing Gear & Bay

Global Hawk UAV

Main Landing Detail



Avionics Bay Structure

Detailed Fuselage Center Structure

Mid-Center Floor Section

Aft Outer Fairing Section

ATR-42 Aircraft

Wall Panel & Seat Cushion


Characteristics

Measurement

type

Scan (1 million

points per

second)

Measure

components of

1 to 30+ meters

Accuracy From 0.5 to 2

millimeters

Fast medium accuracy

measurements, robust,

portable!

23MEASUREMENTS SYSTEMS – LARGE VOLUME 3D SCANNERS

FARO FOCUS 3D AND SURPHASER


24SURPHASERS ON THE JOB

WING SECTION INSPECTION – 3D SCANNING WITH SURPHASER AND LASER TRACKER



Outer Mold Line Surface Mesh ModelTwin Otter Aircraft

Radar Signature Quality NURB Surface ModelOuter Mold Line Surface Mesh Model


Characteristics

Measurement type Noncontact.

Structured (White)

Light Scan

Measure

components of

1 cm to 5+ meters


Rapid, high accuracy point cloud

measurements.

Multiple fields of view.

Can integrate with

photogrammetry

26MEASUREMENT SYSTEMS – BRUECKMANN SCANNERS

Knight’s Helmet Scan Data

STRUCTURED LIGHT SCANNERS - BRUECKMANN


High-accuracy scans

performed by SURVICE

metrologists using the

Brueckmann OptoTOP HE

scanner enable the

inspection and production

of components and

assemblies to very tight

tolerances

27BRUECKMANN SCANNERS ON THE JOB

ROCKET MOTOR FUEL MIXER BLADE ASSEMBLY


28

Cinmar Discovery – Earliest

man made tool found in

America (22,000 years old)

SURVICE scan and 3D print

of ancient artifact

Equipment used: Brueckmann OptoCAT-HE | Software used: OptoCAT and PolyWorks

3D printed replica produced

by Applied Rapid

Technologies

28BRUECKMANN SCANNERS ON THE JOB

STRUCTURED LIGHT SCANNING + ARTIFACT = HISTORICAL FINDINGS


Characteristics

Measurement

type

Scan (1 million

points per

second)

Measure

components of

1 to 30+ meters

Accuracy From 1 to 2

millimeters

Fast medium accuracy

measurements, robust, very

portable!

29MEASUREMENT SYSTEMS: Portable 3D Imager

MANTISVISION F5

SURVICE METROLOGY - BEYOND MEASURE™ 30

• Large-volume scanning technology

• Portable, ruggedized

• IR structured-light scanner in

hand-held, ruggedized form factor

30MANTISVISION F5 ON THE JOB

VEHICLE SCANNING


31

• Ability to accurately capture 3D data

in cluttered and confined spaces

• Rapid data collection

• Minutes vs. hours

• Ease of use

• Post-processing can be done

remotely

31MANTISVISION F5 ON THE JOB

FACILITY SCANNING – BUILDING INFORMATION MODEL (BIM) – REPAIRS / REPLACEMENTS

http://www.mining.com/aveva-laser-modeller-reduces-3d-modelling-time-by-up-to-50/


32

• Rapid data collection & processing

• Scanned in 2 minutes

• 19,971,072 Points

• Processing 30 minutes

(Alignment & Surface Mesh)

32MANTISVISION ON THE JOB

SHIPBOARD SCANNING – SPACE CLAIMS / CONDITION MONITORING / REPAIRS / UPGRADES


• 320kV microfocus source

• 225kV ultrafocus source

• State-of-the-art Perkin Elmer

1621 detector panel

• 0.002mm - 0.5mm resolution

• Material and part size

dependents

COMMON USES:

• Composites/Combat

helmets

• Aluminum castings

• Plastics

33MEASUREMENT SYSTEMS: Xray Computed Tomography

XT H 320LC – 320KV XCT SYSTEM (VIA CHESAPEAKE TESTING)


• 450kV microfocus x-ray source

• 225kV ultrafocus x-ray source

• 37” scanning diameter

• CLDA linear array for 2D XCT

• 0.002mm - 0.5mm resolution

• Material and part size dependent

COMMON USES:

• Armor/Munitions

• Castings/Turbine blades

• Airfoils

• Batteries (Li-Ion, etc)

34MEASUREMENT SYSTEMS: Xray Computed Tomography

CUSTOM 225/450KV XCT SYSTEM (VIA CHESAPEAKE TESTING)


Industries and Applications

Precision

machining and

fabrication

-Cast, forged aluminum, steel,

titanium, etc., part inspections

-Crack, inclusion and void detection

-Turbine blade inspection

Advanced

Manufacturing

-Inspection of Additive Manufactured

parts

-Inspection of composites

Electrical and

Energy Storage

-PCB inspection and reverse

engineering

- Li-Ion Battery inspection

DoD/Test

Support

-Pre- and Post-Test 3D

measurements – helmets, armors

-Non-destructive failure analysis

-Technology Exploitation

35MEASUREMENT SYSTEMS: XCT Scanning and Digital Radiography


36REVERSE ENGINEERING: XCT to CAD

FEATURE-BASED CAD GEOMETRY FEATURE-BASED CAD FILES

Part is scanned using x-ray computed tomography

(XCT) then exported as point cloud and STL.

Feature-based cad geometry is built.

Feature-based cad files are exported into

end-user’s preferred CAD package


37PRINTED CIRCUIT BOARD (PCB) SCANNING

• QA/QC Inspection

• Reverse engineering / component

identification

• Forensics / failure analysis

• Non-destructive, multilayer board analysis


38CONTACT INFORMATION

SURVICE METROLOGY

Atlantic Coast Facility

4603A Compass Point Road

Belcamp, MD 21017

EMAIL:

[email protected]

WEB:

metrology.survice.com

SURVICE METROLOGY

Gulf Coast Facility

1819 Lewis Turner Blvd.

Fort Walton Beach, FL 32547

PHONE:

410-297-2378

PHONE:

850-362-6920