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3D SCANNING
FOR ADVANCED
MANUFACTURING,
DESIGN, AND
CONSTRUCTION
3D SCANNING
FOR ADVANCED
MANUFACTURING,
DESIGN, AND
CONSTRUCTION
GARY C. CONFALONE
JOHN SMITS
THOMAS KINNARE
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any
means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section
107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or
authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood
Drive, Danvers, MA 01923, (978) 750-8400, fax (978) 750-4470, or on the web at www.copyright.com. Requests to
the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River
Street, Hoboken, NJ 07030, (201) 748-6011, fax (201) 748-6008, or online at http://www.wiley.com/go/permission.
Trademarks: Wiley and the Wiley logo are trademarks or registered trademarks of John Wiley & Sons, Inc. and/
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product or vendor mentioned in this book.
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the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a
particular purpose. No warranty may be created or extended by sales representatives or written sales materials.
The advice and strategies contained herein may not be suitable for your situation. You should consult with a
professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other
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Set in size of 9/13 and STIXTwo Text by Integra Software Services Pvt. Ltd, Pondicherry, India
This book is dedicated to our colleagues and coworkers who are always by our side to
help and provide their expertise without hesitation. We would also like to extend our
gratitude to our clients and vendors for providing advice, guidance, and material content
for this book, but mostly for their unparalleled benevolence and friendships throughout
the years. And finally, we especially want to thank our beloved wives and children
for their patience and encouragement during the many evenings and weekends spent
working on this text.
Contents
Preface xi
How to Use This Book xiii
Chapter 5 Post-Processing 85
5.1 Introduction 85
5.2 Coordinate Systems 86
5.3 Scaling 93
5.4 Mapping Techniques 93
5.5 CAD to Part Comparison 97
5.6 Root Mean Square and Standard Deviation 98
5.7 The Method of Least Squares 99
5.8 What Is Uncertainty? 102
5.9 Contributing Factors to Uncertainty 105
5.10 Typical Post-processing Workflow 108
viii Contents
8.4 UAV and AV 165
8.5 Industry Trends 165
8.6 Summary 168
Contents ix
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Preface
For many years additive manufacturing and 3D scanning were considered a futuristic
science seen only in Hollywood movies and television shows. This technology has now
become a reality which has found its way into mainstream society.
Today, with relative ease, folks in this field can explain their vocation in a manner
that others can recognize and appreciate. The career opportunities in this profession are
wide and varying as technology expands the scope of these revolutionary applications
through multiple industries.
3D Scanning for Advanced Manufacturing, Design, and Construction is a result of
many years spent in the field and in the lab throughout the formative development of
this science. The authors combine to bring over 100 years of experience as they worked
in varying facets of this field, and the manner in which it was applied to their area of
expertise. Aerospace, manufacturing, industrial research and development, architecture,
engineering, and construction all use this technology to advance the improvement of
their respective trades. Each of these business segments and many more are explored
with real-world examples. To that we credit our coworkers, clients, and vendors for their
support and advice throughout the creation of this text. Without their experience and
diverse knowledge, the culmination of work in the following pages would not exist.
How to Use This
Book
This book, written for the student, technician, designer, engineer, manager, and other
manufacturing practitioners interested in acquiring and applying 3D scanning technol-
ogies and processes within their organization, aims to provide a broad foundation for
ongoing learning. It covers all aspects of 3D scanning from the history of measurement,
survey, and metrology to the practical applications of 3D scanning as it is used for data
collection, analysis, and reverse engineering. We will explore applications ranging from
radar bore-sighting to architectural engineering and construction with practical, useful,
real-world case studies. The case studies further illustrate 3D scanning technology and
demonstrate methodology through samples of varying applications and solutions without
the burden of detailed theories.
Chapter 2 introduces the basics of laser scanning technology, beginning with a discussion
of lasers, how they are created, what types exist, and the various classifications of laser
instruments. The development of equipment using lasers for measurement will be
reviewed, explaining the basic methodologies employed for scanning.
In Chapter 3 all of the varying instruments used to collect data are described. Laser
trackers, laser scanners, and LIDAR systems are a few of the instruments to be reviewed
for function, purpose, and practical applications.
Chapter 4 begins with a review of the software needed for processing scan data, how the
software functions, and what are key capabilities to look for when comparing software.
The chapter then explores point clouds and polygonal mesh files. What they are along with
best practices for obtaining and processing the data. Data process techniques discussed
include cloud and feature registration, along with polygonal meshing and cross sectioning
for both engineering and architectural modeling as well as CAD to part analysis.
Chapter 5 explains the math behind data processing, analysis, and reporting. Critical to
the application of data collection is the way it is reported to the end user. One must con-
sider scaling and uncertainty to provide accurate and reliable data. Most important is
the ability to report this data in a real-world coordinate system that makes sense to the
designer as well as the end user.
Chapter 6 presents the concept of reverse engineering as used within the manufacturing
and consumer industries. The varied uses of reverse engineering methods are described
along with the use of 2D and 3D CAD modeling techniques unique to industrial
metrology. Case studies are presented, providing the reader with real-life examples of the
applications of laser measurement to modern-day projects.
Chapter 7 presents reverse engineering as used within the AEC (architectural, engi-
neering, and construction) industry. Readers are led through the advantages scanning
provides for modern-day design and construction, along with various applications of this
useful technology, including clash detection, forensics, and BIM modeling. Case studies
illustrate the use of multiple pieces of laser scanning equipment and the diversity of
deliverables used by actual projects to provide timely and cost-saving solutions.
Chapter 8 is a brief analysis of emerging trends within the laser scanning industry, and
what can be foreseen for future development for software, equipment, and applications.
Chapter 9 provides a number of resources and references for the reader, with listings of
professional organizations, equipment, and software manufacturers. Universities and
colleges that offer courses and degrees in metrology and the use of 3D laser scanning
technology are given.
A Glossary of Terms is at the end of the book, a valuable reference for the reader
to understand and define the many specialized terms and acronyms used in the
metrology industry.
Navigating this book, you will be part of the journey in analyzing opportunities for the
application of 3D scanning in your business or industry. Begin by identifying a problem
or opportunity for which you would like to explore a scanning solution. Work through
the major decision steps and post-processing needed to get to the desired end result,
such as a point cloud or a solid model. The case studies will explain how others have
addressed challenges and decisions to move 3D scanning forward in their business work-
flows. By the end of the book, you will be prepared to make a case for implementing 3D
scanning technology into your next project.
History of
Metrology
The regulation of weights and measures is necessary for science, industry, health
care, and commerce. The importance of establishing uniform national standards was
demonstrated by the drafters of the US Constitution, who gave Congress in Article 1,
Section 8, the power to fix the Standard of Weights and Measures. “Weights and
Measures,” said John Quincy Adams in 1821, “may be ranked among the necessaries of
life to every individual of human society.”1
Weights and measures may be ranked among the necessaries of life, to every individual of
human society. They enter into the economical arrangements and daily concerns of every
family. They are necessary to every occupation of human industry; to the distribution and
security of every species of property; to every transaction of trade and commerce; to the
labours of the husbandman; to the ingenuity of the artificer; the studies of the philosopher;
to the researches of the antiquarian; to the navigation of the mariner, and the marches of the
soldier; to all the exchanges of peace, and all the operations of war. The knowledge of them,
as in established use, is among the first elements of education, and is often learnt by those
who learn nothing else, not even to read and write. This knowledge is riveted in the memory
by the habitual application of it to the employments of men throughout life. (John Quincy
Adams, Report to Congress, 1821)
1
Bucher (2004). The Metrology Handbook. https://ebookcentral.proquest.com/lib/umaine/reader.
action?docID=3002524, p. 1–9.
Kilometer km 103
Meter m 1m
Decimeter dm 10 −1 m
Centimeter cm 10 −2 m
Millimeter mm 10 −3 m
Micrometer μm 10 −6 m
Nanometer nm 10 −9 m
By 1795 the Decimal Metric system evolved to recognize the Metre as the stan-
dard unit of measure. This simplistic system soon became a weights and measures law
throughout the globe noting also that a cube having sides of length equal to one-tenth of
a meter was to be the unit of capacity, the liter, and the mass of a volume of pure water
equal to a cube of one-tenth of a meter at the temperature of melting ice was to be the
unit of mass, the kilogram.
Referring to the original standards became difficult over the years so to be more prac-
tical, the platinum bar that was held in Paris to define this metre (meter) was replaced
100 years later in 1889 by the International Geodetic Association with 30 platinum–
iridium bars that were distributed throughout the world. It was not until 1960 that a
new definition was derived using the physical properties of light. The spectral emission
of Krypton-86 radiated light at 606 nanometers (orange) became the new international
length standard from 1960 to 1983.
Today the meter is defined by research performed by the National Institute for Stan-
dards and Technology (NIST) as the length of light travel in 1/299,792,458 of a second in
a vacuum. Table 1.1 lists the SI units of measure commonly used to define length.
1.5.1 Inch
There are many historical accounts of how the inch was derived. Earliest would be the
Anglo-Saxon definition of the inch as being the length of three grains of barley placed end to
end. Later in history, King David I of Scotland and his court of Weights and Measures defined
the inch as the width of an average man’s thumb, measured at the base of his thumbnail.
1.5.3 Hand
Still in use today is the ancient tradition of using the “hand” to measure the height
of horses. Horses from the ground to the top of the shoulder (withers). The unit was
originally defined as the breadth of the palm including the thumb. A statute of King
Henry VIII of England established the hand at four inches. Therefore, a horse that mea-
sures 15 hands would be 60 inches tall at the shoulder (Figure 1.1).
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