7 3D scanning trends in manufacturing
André Voshart
CAD/CAM/CAE General Quality Aerospace Automotive Metal FabricationThese advancements in 3D scanning can help manufacturers capture complex surfaces with ease.
Hexagon’s first handheld 3D scanning devices enable engineers and manufacturing personnel to easily scan what they need in a range of environments. (Credit: Hexagon)
The evolution of 3D scanning technology has been a journey from aspiration to realization, driven by the desire for ease of use and detailed accuracy. Early adopters were drawn to the concept of scanning as a means to understand and analyze parts without physical contact, envisioning a future where intricate details could be captured effortlessly. But the technology initially fell short of these ideals, requiring significant manual input and the use of touch probes for many features and details. Scanning started as an alternative to tactile measurement that sparked interest and led to increased demand—yet it wasn’t always as fluid or user friendly to stand on its own.
Despite these early challenges, the allure of creating precise visual representations of parts has fuelled continuous advancements and development in the field.
Today, 3D scanning technology is finally aligning with the ambitious vision set forth decades ago. Modern scanners have reached a point where they can be operated with minimal expertise, functioning almost like a magic wand that can be waved over a part to produce comprehensive and detailed reports. These devices now provide precise geometric dimensioning and tolerancing (GD&T) data and high-quality visual representations without the need for an industry veteran at the helm.
This leap means that the dream of accurate and user-friendly 3D scanning is now a reality, empowering design engineers and manufacturers to integrate this tool into their workflows.
Creaform’s HandySCAN captures highly detailed measurements, even under challenging environmental conditions and on complex surfaces. (Credit: Creaform)
1. Integration through the entire process
The role of 3D scanning is rapidly evolving from a final quality check to an integral component throughout the entire engineering process. Traditionally, scanning was used predominantly for end-checks, serving as a go/no-go decision point to ensure parts met specifications before they moved to the next stage.
But forward-thinking advancements in 3D scanning technology are shifting this paradigm, enabling the integration of scanning earlier in the design and manufacturing workflow. With the reduction in the barrier to entry and the simplification of the technology, 3D scanning can now be used to gather precise data from the outset, guiding the creation of better parts and more efficient processes.
“There’s definitely a motivation on efficiency, operating costs, and time to market being driven by manufacturers,” said Joel Martin, Hexagon’s director of product management in North America. By incorporating scanning data into the generative design phase, engineers can use intelligent technology to refine and optimize designs from the start, rather than waiting for end-stage validations. This ensures higher quality parts and minimizes rework.
The ability to continuously gather and analyze data throughout the engineering process transforms 3D scanning from a simple verification tool into a crucial element of a closed-loop system, ultimately leading to a more efficient manufacturing practices.
2. For AI—the more data, the better
“The whole concept behind AI is learning,” Martin said. “You have to feed it data,” which enables it to make accurate predictions and decisions. This is where 3D scanning comes into play, enhancing AI’s capabilities by providing rich, detailed data from the physical world.
3D scanning bridges the gap between the virtual and physical realms. By capturing intricate details of objects, these scans offer a wealth of data that AI systems can utilize to refine their algorithms. As noted, feeding AI with high-quality, comprehensive data is crucial for driving processes with precision. The better the data input, the more accurate and effective the AI output.
In practical terms, Martin said that 3D scanning is becoming integral throughout various stages of production: pre-, mid- and post-process. “We’re actually starting to drive the additive manufacturing software to build the right part. That all comes from feeding it closed-loop data.” Instead of relying on theoretical models, AI can work with real-world data, significantly enhancing the accuracy and quality of the final product.
The speed at which 3D scans can be integrated into processes determines how quickly AI can learn and improve. This rapid implementation ensures that AI systems can adapt in real time, continuously improving as more data becomes available.
3. Advanced software functionalities
Advanced software functionalities play a crucial role in helping designers integrate scan data into their workflows. Simon Côté, a product manager with Creaform in Lévis, Que., says improved data processing allows for faster and more efficient integration of scan data into CAD or simulation software. “This advancement not only saves time but also fosters creativity, enabling designers to refine their work to perfection.”
Additionally, 3D scanning supports the shift toward model-based definition, where manufacturing and GD&T information are embedded directly into 3D CAD models, which Côté says “reduces ambiguities and enhances communication across quality control and design teams.”
4. Improved portability
Portability in 3D scanning technology is transforming the design process, particularly in fields where large, immovable parts are common. The issue of “transportability” highlights the need for scanners that function seamlessly across different environments. It’s not just about the size of the scanner; ease of setup, battery life and wireless connectivity are critical factors.
For industries like automotive, aerospace, heavy equipment and wind turbines, Martin says it’s often impractical to bring large parts into a controlled environment. “These are parts that when you go from design and manufacture, you don’t always have the ability to bring the part into a physical location. You have to have a piece of equipment that go into the field.”
Hexagon recently introduced two handheld 3D scanners—the ATLASCAN Max and MARVELSCAN—to complement its range of manufacturing inspection devices. The company’s first handheld 3D scanning devices, they enable engineers and manufacturing personnel to easily scan what they need in a wide range of environments inside and outside factory walls. Both highly portable, the new 3D scanners are ideal for handheld and automated quality inspection applications, and for a wide range of reverse engineering needs.
The portability of 3D scanners empowers manufacturers and designers by removing the constraints of part location. Designers of next-generation wind turbines, for instance, are no longer limited by their ability to inspect and scan prototypes in situ. Portable scanners enable them to capture detailed data directly from the field, informing and accelerating the design and manufacturing process.
“Recent performance improvements have led to handheld and portable 3D scanners replacing traditional 3D measurement tools,” Côté says. “These scanners enhance various stages of product lifecycle management, from design and manufacturing to quality control and servicing. Their ease of use and versatility have significantly boosted their popularity.”
Creaform recently expanded its flagship HandySCAN 3D line-up with the handheld MAX Series line of industrial 3D scanners. “Measuring large and complex 3D surfaces with a handheld device was previously very challenging or, in certain cases, even impossible,” Côté said at the time. “The MAX Series’ unique capability closes the gap and provides innovative dimensional measurement solutions for many manufacturers we’ve met over the years.”
By ensuring tools are easy to transport, set up and operate, the technology helps drive innovation and efficiency in manufacturing next-stage products. The ability to capture accurate data on-site—regardless of the part’s location—represents a significant leap forward in engineering.
5. Increased image processing
Innovative image processing technologies significantly improve data quality, processing time and user experience in 3D scanning. “The integration of artificial intelligence (AI) and machine learning can lead to substantial accuracy and speed enhancements,” Côté says. Furthermore, he says that incorporating augmented and virtual reality can help manufacturers achieve complex tasks more effectively by combining the physical and virtual worlds.
6. Integrating with automation
Automation is essential in the OEM industry due to labour availability, expertise shortages and the need for consistent throughput—and Côté says quality control processes involving 3D scanning must evolve and adapt to this reality. “Automated 3D scanners offer great flexibility and efficiency in quality control. Increasingly, 3D scanners are being integrated with collaborative robots (cobots), facilitating a smooth transition to the ongoing digital transformation in manufacturing.”
What’s more, the use of digital twins enables real-time monitoring and simulation of manufacturing processes, allowing for data-driven decision-making.
7. Avoid getting distracted
In the rapidly evolving field of 3D scanning, Martin says to stay focused on solving the core problem rather than getting distracted by the plethora of available technologies. Engineers should seek guidance from companies that can help them identify the right solutions for their specific needs. Too often, designers try to fit all their quality inspection routines into the capabilities of a single machine, which can be highly limiting. “There are so many tools today—laser trackers, 3D scanning, et cetera—so designers need to try not to pigeonhole one piece of technology to do everything.”
For instance, Martin says Hexagon provides a comprehensive suite of tools that covers every touchpoint in the design and manufacturing process. When exploring solutions, it’s beneficial to consider the root of the problem and which technology will most effectively address it, possibly more so than the one initially considered.
The focus should be on understanding the fundamental needs and exploring how different options meet those needs. “What’s the root of the problem, and what technology will get you to where you need to go better?” Having conversations around the why can help in selecting the best technology for the task, ensuring that engineers don’t get sidetracked by shiny new tools but instead focus on solving the problem at hand with the most suitable solution.
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