A

Project Progress Report

On

3D SCANNING SYSTEM FOR COMPLEX OBJECTS

Submitted to the

Department of Mechanical engineering

In partial fulfilment of the requirements

For the degree of

Bachelor of Technology

By

Sachin Kumar Singh 210110057

Rhythm Yadav 210110052

Sahil Shakoor 210110059

Under the Guidance of

Dr. Rishi Kant

Harcourt Butler Technical University

Kanpur
Introduction:
The rapid advancements in technology, particularly in Industry 4.0, have made 3D scanning systems
increasingly relevant. These systems offer non-contact and non-destructive digital methods for capturing the
physical attributes of objects. The technology is essential in a wide range of industries, including aerospace,
automotive, healthcare, and manufacturing. It plays a critical role in reverse engineering, quality control, and
the design of complex geometries that require high precision [1].

Background and History

The development of 3D scanning can be traced back to its early uses in industrial applications for the
digitization of objects. Over time, advancements in computer-aided design (CAD) and laser technologies
expanded its potential in fields like archaeology, healthcare, and even the entertainment industry for
capturing freeform surfaces and generating highly detailed point clouds [1]. Today, 3D scanners use laser or
structured light to create accurate digital representations of complex objects, which can then be manipulated
using CAD software.

Need for the Study

One of the most pressing needs for 3D scanning technology is the ability to capture complex geometries that
are difficult to model through traditional means. In industries like automotive, medical prosthetics, and
cultural heritage preservation, 3D scanning enables precise measurements, thus improving the efficiency of
reverse engineering and quality assessment. Moreover, with the rise of custom manufacturing and
prototyping, 3D scanners are indispensable in quickly creating digital replicas of objects that can be
analysed, modified, or even 3D printed. The technology also allows for efficient data collection on objects of
varying sizes, from small industrial components to entire rooms.

Industry and Competitive Landscape

In the current market, several key players are pushing the boundaries of 3D scanning technology. Companies
like Artec3D, FARO Technologies, and lead the field with their innovative products. These companies offer
handheld scanners, large-scale scanners, and specialized systems tailored for different industrial needs.
Despite these advancements, the challenge remains to make 3D scanning systems more accessible and
costeffective for smaller businesses and research institutions.
Problem Identification:
The core problem addressed is the high cost and complexity of existing 3D scanners, particularly those used
for scanning complex objects. Traditional 3D scanners are expensive, have limitations in scanning intricate
shapes, and are often inaccessible for small industries or educational institutions. The goal is to develop an
affordable, high-precision 3D scanner that can scan complex objects for various purposes, including reverse
engineering, cultural artifact preservation, and industrial applications.

Core Area of Problem:

I. High cost of existing scanners: Most industrial-grade 3D scanners are prohibitively expensive, as
noted in the first document, with prices ranging from $10,000 to over $200,000[2].

II. Difficulty in scanning complex geometries: Scanning complex objects, such as artifacts, intricate
industrial parts, or medical structures, requires high precision and multiple camera angles to capture
fine details.

III. Limited access for small industries: The current high-end scanners are inaccessible to smaller
businesses due to cost and operational complexity.

Problem Formulation:

To create a cost-effective 3D scanner capable of capturing detailed scans of complex objects, the following
aspects need to be addressed:

I. Affordability: The system should be built from commonly available, low-cost components such as
Arduino units and cameras. The aim is to reduce the cost to a fraction of commercial 3D scanners
while maintaining functional quality.

II. Accuracy: The system must be capable of capturing high-precision scans, particularly of small
features on complex objects. This requires optimizing the resolution and camera placement to
provide comprehensive scanning.

III. Ease of Use: The 3D scanner should be user-friendly, requiring minimal technical knowledge for
operation, and ideally automating much of the scan-to-3D model process.

Related Problems and Their Solutions:

I. Low Scan Resolution:

a. Solution: Use structured light or laser-based scanning methods, which offer higher
resolution and precision for capturing complex geometries.
 II. Slow Processing Times:

a. Solution: Use cloud-based software for fast processing of 3D scans, as seen with tools like
i. Autodesk’s Recap 360.

Prior Studies:
Straub and Kerlin (2014) [3] developed a low-cost 3D scanner using Raspberry Pi and multiple cameras.
Their work highlights the potential for building an affordable system for scanning complex geometries,
though their system was limited by scan resolution compared to high-end scanners.

Findings from Prior Studies:

I. Use of affordable components: Prior research successfully employed low-cost components

like Arduino to create a functional, Higher-resolution, 3D scanner.

II. Applications in Industry 4.0: The study identified various industry applications of 3D
scanning, such as reverse engineering and custom part creation, highlighting the increasing demand
for accessible and accurate 3D scanning solutions.

III. Challenges with resolution: A major limitation of previous systems was the difficulty in
achieving high resolution and precision without significantly increasing costs.

Objective of Study

(a).Cost-effective Development:
Develop a low-cost 3D scanning system that can scan complex objects with intricate geometries. This
will involve using affordable hardware like Raspberry Pi units and cameras, as demonstrated in previous
studies on low-cost scanners.

(b).Optimization for Complex Geometries:

Optimize the scanning system for capturing high-detail data of objects with complex geometries,
including freeform shapes and curved surfaces. This involves improving the resolution and accuracy of
the scans.

(c).Adaptation for Multiple Applications:

Investigate the broader industrial uses of the scanner, including applications in reverse engineering,
healthcare, cultural heritage preservation, and architecture.
(d).Design for Scanning Efficiency:
Enhance scanning efficiency by reducing scanning time, ensuring the system is capable of capturing
full 3D images in a matter of seconds to minutes, as noted in previous studies.

(e).Portable and Flexible System:

Develop a handheld or stationary system that is adaptable to various object sizes, from small industrial
parts to large cultural artifacts.

(f).Minimizing Errors in Complex Scans:

Focus on minimizing errors in point cloud data, specifically when scanning objects with intricate textures
or materials that are challenging for conventional scanning methods.

Scope of Study:

I. Companies: Focus can be on affordable 3D scanner manufacturers like MakerBot, Gotcha 3D

Scanner, and Artec EVA from the list of scanners presented in the papers. These companies provide
varying levels of scanning accuracy and cost, making them ideal for benchmarking affordability
against high-end solutions.

II. Industry: Industries benefiting from 3D scanning include automotive, aerospace, dental, medical,
art, fashion, and reverse engineering sectors, as highlighted in both papers. These sectors often
require precision scanning for custom part creation, digital preservation, and ergonomic design.

III. Time Period: The study could focus on recent advancements in 3D scanning from 2014 onwards,
given the significant technological growth in this area. This can align with the development of
Industry 4.0, which has accelerated the integration of 3D scanning for manufacturing and
digitalization

Methodology Here's a concise Methodology for our project on affordable 3d scanner for complex objects

1. Objective Definition

• The primary goal is to design and develop a low-cost 3D scanner that uses Arduino to control the
scanning process while ensuring affordability and functionality for various applications, including
reverse engineering, object digitization, and 3D printing.

2. Hardware Components

The hardware selection for the 3D scanner emphasizes cost efficiency, flexibility, and ease of assembly. The
following key components are chosen:
 • Arduino Board: An Arduino Uno or Mega is selected for its simplicity in controlling sensors and
motors. The Arduino is like the brain of your scanner. It controls everything – it tells the motor when
to turn, reads the sensor data, and makes sure everything works together. It automates the scanning
process by rotating the object and collecting data.

• Stepper Motors: Used to rotate the object or move the scanning sensors in a controlled manner. A
stepper motor is type of electric motor that divides a full rotation into discrete steps, allowing for
precise control of position and speed. Here it used to control the linear motion of the IR sensor
module step by step to ensure the accurate and well covered scanning

• IR Sensing module with integrated camera: A standard webcam or an infrared sensor to capture
images for 3D model reconstruction. This sensor measures how far the object is from the scanner. It
sends out infrared waves and measures how long they take to bounce back. By taking measurements
from different angles, it helps create a 3D map of the object.

• DC12V HIGH TORQUE LOW RPM MOTOR: A DC 12V high torque low RPM motor is an
electric motor designed to operate at 12 volts, providing significant torque at low rotational speed. In
our project it is used to rotate the circular platform where the test object is places whose 3D scanning
it to be performed.

• SD Card Module: This is where the scanned data is saved. As the scanner collects information (like
distances or angles), the Arduino saves it on an SD card, so you can use it later to build a 3D model
of the object.

• Stepper Motor Driver: This parts controls the motion of motors. It helps the motor to move
smoothly and precisely. It makes sure the motor turns in tiny steps, which is important for scanning
object with high accuracy.

• Frame and Mounts: The frame for the setup will be constructed from low-cost PVC or 3D-printed
parts, ensuring it is lightweight and easy to assemble.

3. Software Integration

• Arduino IDE: Used for programming the Arduino to control the stepper motors and sensors.

• MeshLab or Autodesk Recap: For processing and post-processing the point cloud data into a 3D
model.

4. Design and System Architecture

• Step 1: Object Placement: The object is placed on the turntable, which is connected to a stepper
motor controlled by the Arduino.
 • Step 2: Scanning Operation:

o A infrared sensor scans the object’s surface as it rotates on the turntable. o

The camera captures the reflected structured light, which Arduino interprets to

calculate the object’s surface geometry.

• Step 3: Data Transmission:

o The Arduino sends the captured data via serial communication to the computer.

• Step 4: 3D Model Generation: Post-processing is done using tools like MeshLab or Autodesk
Recap to create a 3D model.

• Step 5 : Model Storage: Processed model is stored in the sd card via SPI (Serial Peripheral
Interface)

5. Development Process

• Prototyping:

o Begin with designing the mechanical structure, ensuring the camera and laser module are
securely mounted to capture accurate data.

(a) (b)

(c)
 F Figure: CAD model for proposed 3D scanner (a) Top view (b) Side View (c) Isometric view

Specifications of the components used:

o Arduino Uno: Microcontroller board based on the

ATmega328P. It operates at 5V and has 14 digital
input/output pins, 6 analog inputs, a 16 MHz quartz crystal,
and a USB connection.
o Infrared Proximity Sensor Long Range - Sharp
GP2Y0A02YK0F: Infrared distance sensor capable of
detecting objects within a range of 20 to 150 cm. It
provides analog output proportional to the distance
measured.
o Stepper Motor: A type of motor that moves in discrete
steps, with typical specifications of 1.8° per step and
operating voltage around 5-12V. Suitable for precise
positioning applications.
o Stepper Motor Driver: A driver for stepper motors that
operates at 7V to 30V and can provide up to 750mA per
phase. It allows microstepping control and interfaces
easily with microcontrollers.
o DC12 MOTOR- 90 RPM (6-12V): A DC motor with a
gearbox, providing a speed of 90 RPM at a voltage range
of 6 to 12V. It offers high torque and is suitable for slow,
precise movements.
o Micro SD Card Module: Typically supports SD cards
up to 32GB in FAT16/FAT32 format.
Circuit design of scanner:

DC12V Motor
Stepper motor
Infrared sensor

SD card
module

Arduino Stepper Motor Driver

Board

Electronic Circuit Diagram of 3D Scanner

Cost analysis:

o Arduino Uno: ₹599 - ₹799

o Micro SD Card Memory Shield: ₹180 - ₹350.
o 330 Ohm Resistor (Pack of 10): ₹20 - ₹50.
o Infrared Proximity Sensor (Sharp GP2Y0A02YK0F): ₹750 - ₹1,000.
o Diode Rectifier - 1A 50V (Pack of 10): ₹30 - ₹70.
o Micro Geared Motor (90 RPM): ₹180 - ₹300.
o EasyDriver - Stepper Motor Driver: ₹300 - ₹450.
o Micro SD Card Memory Shield: ₹180 - ₹350.
o 330 Ohm Resistor (Pack of 10): ₹20 - ₹50.
o Infrared Proximity Sensor (Sharp GP2Y0A02YK0F): ₹750 - ₹1,000.
o Diode Rectifier - 1A 50V (Pack of 10): ₹30 - ₹70.
o Micro Geared Motor (90 RPM): ₹180 - ₹300.
o EasyDriver - Stepper Motor Driver: ₹300 - ₹450.
o USB Cable A to B: ₹100 - ₹150.
o Breadboard: ₹80 - ₹150.
o Infrared Sensor Jumper Wire (3-pin JST): ₹50 - ₹100.
 o Jumper Wires Pack (M/M): ₹50 - ₹100.
o Male Headers Pack: ₹30 - ₹70.

Total Cost = ₹ 3019 - ₹ 5759

Conclusion:

We have proposed and developed a 3D scanner model that is cost-effective and capable of capturing
complex geometries with high precision. The 3D model of the scanner was designed using Blender, and
its circuit design was created on Circuit.io. By utilizing affordable components such as Arduino, stepper
motors, and infrared sensors, the prototype addresses the high cost and inaccessibility of commercial 3D
scanners, making it suitable for small businesses and educational institutions.

The processing and post-processing of the scanned data were conducted using MeshLab and Autodesk
Recap 360, ensuring the creation of accurate and detailed 3D models. The testing and validation of the
scanner's performance will be carried out in the next phase of the project to evaluate its effectiveness in
various applications, including reverse engineering, cultural heritage preservation, and healthcare.

References

1. Straub, J., & Kerlin, S. (2014). Development of a Large, Low-Cost, Instant 3D Scanner.
Technologies.
2. Haleem, A., Javaid, M., Singh, R. P., Rab, S., Suman, R., & Kumar, L. (2022). Exploring the
potential of 3D scanning in Industry 4.0: An overview. International Journal of Cognitive Computing
in Engineering.

3. Haleem, A., Javaid, M., Singh, R. P., Rab, S., Suman, R., & Khan, I. H. (2022). Industrial
Perspectives of 3D Scanning: Applications and Advancements in Manufacturing. International
Journal of Cognitive Computing in Engineering.

Project Guide Sign…………………