Thursday, July 12, 2012

3D Model Surface Preparation for Laser Scanning

3D Model Surface Preparation for Laser Scanning

Customers can reduce the cost of laser scanning by doing their own surface preparation.

The ZScanner 800 (Creaform EXAscanner) is a versatile scanner capable of .2mm resolution and up to .04mm accuracy. One drawback to this scanner is that it is sensitive to surface color and specularity. Colors like red and black are difficult to scan and highly reflective surfaces can be impossible to scan. Proper surface preparation can improve feature detection, scanning speed and scanning accuracy.

The ideal surface for scanning is smooth, white and matte. As colors get darker, scanning speed decreases; a black surface can take 4 or 5 times as long to scan as a white surface. As surfaces get more specular (shiny), scanning noise increases; a highly reflective surface is all noise and no signal making it impossible to scan. And the scan data is always rougher than the surface, as surfaces get rougher, it becomes harder and harder to resolve features.

Of course, before any surface preparation can be done, the part to be scanned must be thoroughly cleaned and dried. Once this is done, the surfaces can be prepped in 1 of 4 ways:

1. Painting

Painting is the method of choice. Aerosol paint is relatively easy to apply and covers well. For scanning accuracy, Krylon Gray Primer is best. For scanning speed, Krylon Flat White works well. Whichever is chosen, the paint should be applied as thinly and as evenly as possible. Usually .0006" to .0010" is plenty. Of course the paint thickness alters the scanning results, but the results can be offset in software by the paint thickness, which will cancel out the paint thickness. But only one thickness value can be entered so it’s important to keep the thickness uniform.

Of course paint can only be used on parts that you don’t mind being painted or which are sturdy enough to hold up to removing the paint. Methyl Ethyl Ketone (MEK) will remove paint easily, but will damage many surfaces and dissolve some plastics. Be sure to read the safety precautions on the MEK container before using.

2. Powder Coating

An aerosol powder like Magnaflux SKD-S2 can be applied much like aerosol paint. The difference being that the powder is easily removed by rinsing, brushing or blowing off with compressed air on most surfaces. The powder is diatomaceous earth, which are essentially tiny silicon crystals. It’s nearly impossible to get out of porous materials and it can be very abrasive making it a poor choice for mechanical assemblies and mechanisms. The propellant can also slightly alter some finishes, especially painted surfaces and plastics.

Being easy to remove also means having to handle the part with extreme care. Even the slightest bump or breeze can knock off the powder.

3. Waxing

For high quality painted surfaces or plated surfaces, a light coat of paste wax works pretty well. Just apply the wax and let it dry to a haze. The thicker the better, but I’ve scanned chromed handle bars with only a very light coat of wax. Once the part has been scanned, just wipe/polish off the wax.

While this method works, the scanning rate is usually much slower than with paint or powder.

4. Replicate Casting

Replicate casting is used when the part is too complex for wax and too important or too delicate for paint or powder. Special low shrink silicone rubber is used to make a negative of the part and then the negative is scanned instead of the part. This method is also used to scan internal features that the scanner can’t normally "see".

Replicate casting can significantly increase the time and cost to process a part and is usually the method of last resort.

Not all surfaces require preparation prior to scanning. But for surfaces that do require it, customers can save money by doing as much of the preparation as possible.

Sunday, April 15, 2012

3D Model Laser Scanning Multiple Times

3D Model Laser Scanning Multiple Times

Scanning a part multiple times can significantly increase the accuracy of the finished model.

A customer needed to reproduce some inserts for an automotive injection mold. Attempts to build them using their customer's CAD models failed because the inserts didn't match the models.

The inserts had advanced surfaces that had to match exactly with neighboring surfaces in the mold. This made the project ideal for laser scanning except that the accuracy required was about twice that of what my laser was typically capable of using a single scan. By scanning the inserts four times each and then averaging the scans, we were able to achieve the desired accuracy.

In a measuring system, if the measurement error is randomly distributed about zero, measurement uncertainty can be reduced as a function of the square root of the number of measurements made and averaged. In other words, if you measure something four times, the average of those measurements will have half of the uncertainty of any one measurement.

As part of Reverse Austin's monitoring of laser performance, I periodically scan and measure a CMM training standard. From the many measurements I've done, I can see that the measurement error is random and fairly well distributed about zero. If I chart the error from the averages of any four consecutive scans, I get errors that are a little less than half of the errors from individual scans.

If you've done your homework and you know the uncertainty of your scanning system, you can significantly improve accuracy (reduce uncertainty) by scanning multiple times and averaging the scan data.

Saturday, March 17, 2012

3D Model Laser Scanning for Molding and Casting

3D Model Laser Scanning for Molding and Casting

Laser Scanning can have big payoffs for Molders, Mold Makers, Foundries and Pattern Makers.

1. Faster mold qualification with fewer development cycles, especially for overmolding.
2. Reuse of existing geometry from previous projects.
3. Precise capture of customers' prototype geometry.
4. Protection of legacy tooling.

Instead of relying on a few gauge points, laser scanning captures the entire part. By comparing the scan data to the nominal CAD model, the amounts and locations of all deviations can quickly be determined. When correcting overmold problems, the scan data can be used to create solid (CAD) models of the parts going into the overmold tooling. These models can be used to modify the overmold tooling to provide precise matches and/or crushes to eliminate shutoff failures.

When building new tooling to replace or supplement existing tooling, like going from single cavity to multi cavity, laser scanning can be used to create accurate CAD models of the existing tooling. The models can then be used to machine molds, electrodes or patterns. When the new tooling is complete, it can be scanned and the scan data compared to the original scan data to confirm that the new tooling precisely matches the old.

Customers don't always have complete CAD models for their products; they may only have hand made prototypes or they may have machined parts with hand made modifications. Laser scanning can be used to create accurate high quality CAD models that can be used to machine molds, electrodes or patterns. Before any tooling is built, the CAD models can be used for Additive Manufacturing (rapid prototyping) to produce models for customer approval.

Many shops have tooling that predates their current CAD system. Even if compatible CAD models exist, the models may not include all the "tweaks" that were done to make the tooling perform. Laser scanning can capture the existing geometry including any tweaks. The scan data can be stored as STL for later use or it can be used to develop compatible CAD models. In the case of a catastrophic event, tooling can be rebuilt.

Laser scanning can be a cost effective tool with large ROI. Contact me and let me explain how.

Tuesday, March 13, 2012

3D Model Restless Legs and BPA

3D Model Restless Legs and BPA

Eliminating BPA from my diet appears to have made a significant improvement in my RLS symptoms.

Essentially all canned foods and beverages contain BPA as do foods and beverages stored in containers made of polycarbonate (recycle code 7). A recent Harvard study showed that eating canned soup five days in a row raised BPA levels in urine almost 1300%.

For years, I've suffered from RLS. Recently, the symptoms became so severe that they were affecting my ability to work. After reading about the Harvard study and, separately, about a possible link between BPA and RLS, I decided to eliminate BPA from my diet; no canned foods, no canned drinks, nothing stored in plastic containers with a recycle code of 7. Also, no restaurant foods that may have canned origins like tomato sauces.

The change in my RLS symptoms has been dramatic. While there is no scientific proof that eliminating BPA helps RLS, it's something that's easy to do. For me, it has been well worth the effort.

Wednesday, February 29, 2012

3D Model Reverse Engineering for Reshoring

3D Model Reverse Engineering for Reshoring

Laser scanning based reverse engineering is a powerful tool for reshoring.

It's sad, but true that many products being manufactured overseas were at least partially engineered overseas. It's very common for molds and tooling for US products to be designed by and be owned by overseas manufacturers.

The overseas manufacturers often develop and build tooling at "no cost" which makes it easier to get started, but nearly impossible to leave. If a customer wants to move a manufacturing operation, he or she is often faced with having to redesign and rebuild all of the tooling. Laser scanning can help.

Often the tooling development process results in small tweaks to the part design. And often these tweaks go unnoticed and don't get incorporated into the official design. Trying to build new tooling doesn't just involve redesigning the tooling, but also redesigning the part. And that's where laser scanning based reverse engineering comes in.

3D laser scanning (or X-ray CT scanning) can collect enough measurement data to completely describe a part. The scan data can then be processed with advanced reverse engineering software, like Rapidform, to create high quality, dimensionally accurate CAD models. These models can be used for designing tooling, design documentation and quality control.

Think about laser scanning the next time you're involved in a reshoring effort.

Saturday, February 11, 2012

3D Model Texas Medical Device Alliance and STL

3D Model Texas Medical Device Alliance and STL

I attended my second TMDA meeting on February 9, 2012. The presentation by David K. Leigh was especially interesting.

David spoke on the evolution of design and manufacturing and the role of additive manufacturing in the evolution. He also spoke of the need of and ongoing efforts to develop formal specifications for additive manufacturing processes.

Later, via email, David pointed me towards information on the ongoing development of a replacement for STL. Originally dubbed STL 2.0, it's now named AMF. The format promises to significantly increase resolution while simultaneously reducing file size. Additionally, there are discussions on adding the ability to include voxel data (3D bit-maps) commonly used by medical imaging equipment and industrial CT scanners.

David K. Leigh is the president of Harvest Technologies in Belton, Texas.

Wednesday, January 11, 2012

3D Model Reshoring with Laser Scanning

3D Model Reshoring with Laser Scanning

Laser scanning can be a vital tool in bringing manufacturing back to the US.

A customer of one of my clients wanted to reshore a line of fishing lures. Production was continuing overseas so the molds were not available. Also, due to the high level of rework required on the lures, it was felt that the overseas molds would not be adequate for US production. My client's customer chose to have new molds built here.

My client, an injection molding company, had already begun production of one lure in the series. Reverse engineering the first molds using conventional methods was very time consuming and required several mold revisions to achieve an acceptable product. Repeating the process on the other lures in the series was going to be prohibitively expensive so Reverse Austin was contacted to see if the process could be expedited using laser scanning.

My client had had less than satisfactory experience with laser scanning performed by a previous vendor. The CAD models produced were comprised of many small surface patches that included small imperfections and which were difficult to tool path.

To show my client that not all laser scanning is created equal, I grabbed an old lure from my tackle box and scanned and modeled it. Based on the results, my client agreed to have me scan and model two of the remaining lures in their customers line.

My client had SLA rapid prototypes made from the Reverse Austin CAD models and submitted the prototypes to their customer for approval. The prototypes were approved and my client has started building the molds.

Thursday, December 8, 2011

3D Model Laser and X-ray CT Scanning Projects

3D Model Laser and X-ray CT Scanning Projects

I'm often asked "What is scanning used for?".

I use 3D laser scanners and X-ray CT scanners to create dimensionally accurate CAD models of physical objects (parts) and to perform dimensional analysis and non destructive testing (NDT). The parts generally fall into one of two categories; old stuff and new stuff. The old stuff usually involves CAD modeling and the new stuff dimensional analysis and/or NDT. The following are a few examples:

A foundry making investment cast fire sprinkler heads needed to increase production on an older model head. The foundry wanted a multi cavity mold that would produce wax patterns that were identical to the ones produced with the old single cavity mold. During the development of the original head, the single cavity mold had been modified based on customer requirements and the parts coming out of the mold were significantly different from the old drawings. I was able to laser scan one of the wax patterns and create a solid CAD model that replicated the pattern precisely. The customer then scaled the model for shrinkage and cut a new multi cavity mold. According to the customer, "The parts from the new mold are indistinguishable from the old".

A contract manufacturer specializing in aircraft structural components needed to machine a replacement for a 4' long section of cracked longeron from a commercial airplane. The standard procedure was to use a profile mill to machine a replacement by tracing the profile of the old longeron. The manufacturer had gotten rid of the ancient profile mill in favor of new CNC equipment and had no way to machine a new longeron without a CAD model. I was able to laser scan the cracked longeron and a plaster cast of part of the longeron still in the aircraft and then create a solid CAD model of the replacement with an integral doubler (splice). The customer machined the replacement part and "it dropped right in".

A contract manufacturer machining a family of parts for a long time customer damaged a functional gage for one of the parts. A new gage fabricated to print produced parts that weren't functional. Investigation found that many of the other functional gages weren't made to print even though parts made to them were functionally acceptable. I was able to scan and model the gages to enable the shop's drafting department to produce accurate drawings and to aid machining of new ones in the event of another mishap.

A firearms manufacturer cracked a set of forming dies used on one of its most popular pistol magazines. The dies had been tweaked to provide parts that functioned reliably and did not exactly match the CAD models originally used to make them. Prior to the accident, the manufacturer had already had me scan and model a magazine in preparation for designing new and improved dies. Unfortunately, the accident accelerated the project and necessitated a more direct approach. I was able to scan and model the old dies so that new ones could be machined immediately.

As part of a reshoring effort, an injection molding company needed to design and fabricate molds for a sporting goods item. The original molds were made to match hand carved prototypes and no drawings or models were available. I was able to laser scan and model one of the parts produced overseas so that new molds could be produced here.

A manufacturer of high end kitchen utensils was having problems with unacceptable overmolding on one of its product handles. The problem was caused by mismatch between the parts coming out of the primary molds and the overmold tooling. I was able to laser scan and model some parts from the primary molds. The CAD models included the shrinkage and warping found on the parts. The models were used to re machine the overmold tooling to precisely match the parts. This has since become the manufacturer's de facto method for debugging overmold problems.

A medical device manufacturer wanted to shorten the development time on a new delivery system. The system was an assembly of ultra precision injected molded parts with extremely small features. Previously, similar systems had required many iterations of mold tooling designs to achieve the desired product quality. Using X-ray CT scanning I was able to create very precise, ultra high resolution CAD models of the as-molded assembly components. I then 'assembled' the components in CAD and used fly throughs, sections and interference checks to determine the required modifications and eliminate many mold iterations.

The above are only a few of my scanning projects, but perhaps they give some idea as to "What is scanning used for?". For more details.

Tuesday, November 8, 2011

3D Model to Raise Taxes

3D Model to Raise Taxes

The best way to stimulate the US economy and reduce the US government deficit is to raise taxes.

Before I go any further, I want to say that I truly believe that government spending needs to be thoughtfully reduced. The government "wastes" a lot of money through lack of effective oversight and that waste should be eliminated to the greatest degree possible. But that would not stimulate the economy and would only slightly reduce the deficit.

The "economy" (US, EU, etc) is the mechanism by which goods and services are distributed. When it's working well, a very large percentage, nearly all, of the people are able to obtain goods and services in a timely manner without undue sacrifice. When the economy is working poorly, as it is now, a smaller percentage is able to obtain these benefits. What's an acceptably large percentage? What's an unacceptably small percentage? I think you and I will agree that if the percentage doesn't include us, you and me, it's too small.

Goods and services are distributed by a sophisticated and complex bartering system that uses currency (dollars) as its exchange mechanism. When I obtain goods and services from you, I exchange them for currency, which you then use to obtain goods and services, and visa versa. The currency is simply a promise to exchange goods and services. The currency has no value on its own. Without my promise to exchange something in return for currency, the currency has no value to you. A dollar without people is entirely worthless, it only has value when you and I agree that it can be exchanged for something else. Without us, you and me, the dollar is not even worth the ink and paper it's printed on, because most of our currency, most of the dollars, don't even exist - most are simply numbers in a ledger or computer - most were never printed and never will be.

Not only do we have to agree to exchange currency, we have to actually exchange it, keep it moving. If currency piles up in one or more spots, it stops working. If I collect currency from you and never exchange it, if I horde it, I've broken my promise to exchange it and it becomes worthless. When I have all the dollars and you have none, you have no reason to exchange services or goods for dollars. You would be better served by picking a new exchange mechanism, like navel lint, where you and I both start out with pretty much the same amount.

Currency has its greatest exchange value when it's moving freely. It has zero value when it stops moving. When it's moving sluggishly, like now, its exchange value is somewhere in between. Stimulating the economy means causing money to move at a rate that yields an acceptable value. What is that value? Once again, you and I will agree that it's too low if we have to sacrifice to obtain the goods and services that we need to thrive.

Right now, currency is not being exchanged at an acceptable rate, it is pooling up with the wealthiest companies and the wealthiest people. For instance, Google was recently published to have over 42 billion dollars in cash and equivalents. What will it take to get this currency moving? What about incentives? Google is already working as hard as it can to become as big as it can. Will giving Google monetary incentives, giving Google more money, cause Google to create more Jobs? Currency loses value as it pools and Google already has a really big pool. It would take a huge monetary incentive to get Google to even notice it and then they wouldn't be able to try any harder than they already are.

One way to keep currency moving and stop dollars from pooling is to take it, in the form of taxes, from those who have large amounts of it. By some estimates, for every dollar the government spends on goods and services from US companies, the GDP increases by $.70 to $1.50. Right now, the government is spending lots of money on interest because of the deficit. By raising taxes, less money could be spent on interest and more could be spent on goods and services. That spending would stimulate the economy, but so would the companies and people from whom the taxes are collected.

Corporations are not autonomous entities working on cool logic to maximize revenue. Corporations are managed by people who seek to obtain a higher standard of living. A man with a full belly has little incentive to gather food, but a man who has had a full belly and whose belly is now empty has a lot of incentive to find food. The idea that taking money from someone who is accustomed to having it is going to cause that person to want it less, to become less productive, is naïve and demeaning. The people that make our country great are not going to lie down because they have to pay more taxes, they are going to rise to the occasion and make more money to maintain their standard of living. And by doing so will create new jobs and stimulate the economy.

Stimulating the economy means causing currency to move faster and to pool less. An effective way to accomplish this is to raise taxes on currency that isn't moving. Taxing income and/or sales is counter productive - earning and spending moves currency and should be encouraged, not taxed. Collecting huge cash pools and properties should be taxed, not eliminated, just taxed. A well thought out cash, cash equivalents and property tax could benefit all, including those paying the taxes.

Friday, October 21, 2011

3D Model Bolt Remover

3D Model Bolt Remover

Irwin bolt removers work great.

While trying to remove the blade from a neighbor's Honda lawn mower, I broke a 6 point 14mm socket wrench and rounded off the bolt head in the process. I went to the local home and garden store and picked up a set of Irwin bolt removers. I used a hammer to tap the 14mm remover onto the bolt head and then tried to remove the stuck bolt. I wasn't successful, but not because of the Irwin bolt remover, it didn't slip a bit. With a 18" breaker bar and a 12" cheater pipe, I was afraid that I was going to break off the bolt if I applied any more torque.

Friday, September 30, 2011

3D Model Lifecycle of Money

3D Model Lifecycle of Money

"Money doesn't grow on trees" i.e. money isn't free, is pretty widely accepted - a business has to sell services or goods to make money. Perhaps not so obvious is that, in a business, money has a lifecycle and that lifecycle costs money.

Let's look at a generic company that operates entirely off of its cash flow and doesn't use credit for day to day operations. A simplified money lifecycle might look something like the following where:
'F' = funds (postage, shipping, etc)
'L' = labor
'M' = materials (forms, boxes, etc.)
'T' = time

Lifecycle Start
1. Get Money
   a. Customer Purchase Order Processing
      1. Receive PO   (L, T)
      2. Issue Shop Orders   (L, M, T)
   b. Fulfillment
      1. Pull Inventory   (L, M, T)
      2. Box and Ship   (F, L, M, T)
   c. Customer Invoicing
      1. Create and Send Invoices   (F, L, M, T)
      2. Wait for Payment   (T)
   d. Customer Payment Processing
      1. Receive and Process Payments   (L, M, T)
      2. Reconcile Delinquent Accounts   (F, L, M, T)
2. Keep Money (for some time period)   (T)
3. Spend Money
   a. Purchase Order Processing
      1. Generate Purchase Requisition   (L, M, T)
      2. Create and Send Purchase Orders   (F, L, M, T)
   b. Receive Goods
      1. Receive and Reconcile Shipments   (L, M, T)
      2. Receiving Inspection   (L, M, T)
   c. Invoice Processing
      1. Receive and Reconcile Invoices   (L, T)
      2. Issue Payment Request   (L, M, T)
   d. Payment Processing
      1. Generate and Send Payments   (F, L, M, T)
      2. Reconcile Accounts   (L, M, T)
Lifecyle End

If F, L, M and T all cost money, then the value of a dollar on a customer's PO is significantly reduced by the time it's spent i.e. when its lifecycle has ended. If a company only has one product and one customer, then the reduction in value may be fairly constant. However, if a company has multiple products and/or multiple customers, it is very unlikely that the cost will be constant.

Costs that vary by product or customer are not "overhead". If a company fails to understand the different costs, the company has no hope of maximizing its profit, it will invariably create undesirable price customer combinations. Customers being charged too much may leave. Customers being charged too little may bleed the company dry.

Sunday, September 18, 2011

3D Model FANUC Program Transfer

3D Model FANUC Program Transfer

FANUC's Program Transfer Tool does a great job on CNC programs and offsets, but not so great on CNC control parameters. Download and install Fanuc2Numbers to convert parameters like "[26312*65536+46138]/[67108864*32]" into ordinary numbers like "0.80300".

1. Use the Program Transfer Tool to download the control's parameter file to a PC.
2. Start Fanuc2Numbers and "Agree" not to hold me responsible if something goes wrong.
3. Select the "Fanuc" button and browse to the parameter file you downloaded.
4. Select the "New" button and enter a filename for the converted parameters. If you use the same name, it will over write the original file.
5. Select the "Convert" button and you're done. The new file will contain only ordinary numbers.

Wednesday, September 7, 2011

3D Model Scanner Resolution vs Feature Size

3D Model Scanner Resolution vs Feature Size

The size of a feature that can be reliably detected by a laser scanner is significantly larger than the scanner’s resolution.

A scanner’s resolution or point density is a measure of how closely points are spaced on the surfaces being scanned. A scanner with a resolution of 50µ (.050mm) will record a point every 50µ if the scanner is perpendicular to the surface being scanned. As it is not generally possible to always scan perpendicular to all surfaces, the scan angle should be taken into account. For instance, at an angle of 45 degrees, the distance between points increases to approximately 71µ. Once the point spacing is known, detectible feature size can be calculated.

The laser never captures 100% of any feature and the closer the point density is to the size of the feature, the lower the percentage of capture. A 1mm feature scanned with 70µ point spacing can be detected to 93% and a 0.5mm feature to 86%. Conversely, the size of the feature can be calculated. For an 80% capture with 70µ point spacing, the feature must be at least 0.35mm.

Saturday, August 13, 2011

3D Model New SolidWorks User

3D Model New SolidWorks User

A new client requires that I supply all CAD files in SolidWorks with intact feature trees. The project is large enough that it warranted purchasing a seat. The project's schedule is fairly aggressive and I had to come up to speed with the new software as quickly as possible.

I plowed through a couple of tutorials and went to work on my client's project. Although certainly not a power user, I am able create relatively complex geometry and assembly constraints with little fumbling.

The interface and workflow are very similar to Rapidform XOR, which is my primary CAD modeling tool. Rapidform has extensive tools for working with meshes and point clouds and for reverse engineering. And it will continue to be Reverse Austin's primary CAD package, but I'm very impressed with the functionality and ease of use of SolidWorks.

Friday, July 8, 2011

3D Model - When Calibration is a Bad Thing

3D Model - When Calibration is a Bad Thing

Equipment and instrument calibration is not an acceptable substitute for process feedback.

I once worked with a very intelligent Quality Assurance (QA) engineer. In a discussion where he was espousing the virtues of mandatory periodic equipment calibrations, he made the statement "I never buy tires from a company that doesn't provide alignment services. I always have my car alignment checked when I buy new tires." He was quite certain that this analogy supported his argument that periodic equipment and instrument calibrations were essential.

The concept argued by the QA engineer is that all things that may require adjustment or calibration have to be checked and adjusted on a periodic basis by qualified technicians using specialized equipment. Belief in this concept is ubiquitous in today's QC systems and is even dictated by many regulatory bodies including the United States FDA.

Back to the car analogy: Let’s suppose that I'm taking my car in to get new tires after having gotten 60,000 miles on my old ones. Further, let's say that the tires all wore evenly, that the car drives straight and true and that the car's gas mileage has been constant and is acceptable. Should I have someone check and adjust the wheel alignment?

The purpose of wheel alignment is to insure that the tires track true to the vehicle's path so that the car drives straight, the tires wear evenly, the tires last a long time and the vehicle gets good gas mileage. If these conditions are true, why let someone adjust the alignment? No matter how well trained and no matter how specific their equipment, they are not going to make things any better and they might make things worse. If these conditions are not true, why did I wait until now to do something about it?

A successful process requires timely feedback. Waiting until my tires are worn out to check my alignment is not timely. I should visually inspect my tires as I walk up to the car, not only for wear, but for proper inflation. When I drive, I should be aware of unusual or unacceptable behavior like pulling or drifting. And when I fill up at the gas pump, I should check my gas mileage to verify that nothing’s amiss with the engine or drive train.

Time and time again, I've seen processes go haywire after mandatory equipment calibrations. I’ve also seen "validated" processes, using calibrated equipment, drift out of specification. Measurement processes are especially vulnerable. It's common to see measurement processes go unmonitored and reliant solely on periodic calibrations.

Do not rely on equipment calibrations to insure process integrity. Find timely feedback mechanisms and use them to monitor processes. Use calibrations as diagnostic tools, not as process controls.

Saturday, June 25, 2011

3D Model Overmold Scanning

3D Model Overmold Scanning

3D Scanning can be a very powerful tool for correcting overmold problems.

Flash and/or failure to shut off in overmolding is often caused by a poor fit between the part and the mold. Scanning can provide an easy and straightforward method to correct the fit.

The part to be overmolded is scanned and enough data is collected to accurately describe the part. Software such as Rapidform is used to create a solid model (CAD model) of the part including all the shrinkage, warpage, etc. The end result being a CAD model that accurately represents the part to be overmolded. The model is then used to redesign and modify the overmold tooling to fit the part precisely.

Tuesday, June 7, 2011

3D Model Dimensional Inspection

3D Model Dimensional Inspection

X-ray CT scanning and 3D Laser scanning are ideal for dimensional inspection of components, especially when ergonomic or freeform shapes are involved.

Modern CAD software is not limited to prismatic features. Designers are able to incorporate a wide variety of shapes that often defy inspection without the use of scanning. This is especially true with injection molded components.

When diagnosing overmolding problems or assembly issues on parts with complex surfaces, scanning is often the only way to collect enough data to accurately characterize the components and find the problems. Sometimes it's even beneficial to "reverse engineer" the molded component and create a solid model (CAD model) with shrinks, checks, warps, etc intact.

Tuesday, May 24, 2011

3D Model AVAST XP 64-bit Problem

3D Model AVAST XP 64-bit Problem

"There could be an issue with your operating system probably" is the AVAST support response to this issue.

Due to the nature of my work, I run Windows XP 64-bit. I've been using AVAST anti virus software for 3 years and until recently, I've been a big fan of their product. But starting with the release of version 6, I've been having problems with updates. Some virus database updates corrupt my system and prevent the system from booting, causing it to hang during the boot process.

To fix this issue I have to:
1. Boot in Safe Mode
2. Un-install AVAST
3. Boot normally
4. Re-install AVAST

After the above, the system will behave normally until another AVAST update. Not every update causes a problem. In fact, most don't, but 4 times in the last month I've had to recover using the above procedure.

A Google search on this issue reveals that I'm not the only one with this problem. If you're running XP 64-bit and looking for anti-virus software, you might do well to look at something other than AVAST.

Tuesday, May 10, 2011

3D Model Rapidform XOR Certified

3D Model Rapidform XOR Certified

I just got word that I'm certified in Rapidform XOR. I'm not completely sure what the certification means other than that I passed the 2.5 hour long on-line proficiency test. The test was also a prerequisite for attending the advanced training classes at this year's Rapidform Success conference, which I did.

So if I was already certified before I took the advanced classes...

Thursday, April 21, 2011

3D Model Rapidform Success

3D Model Rapidform Success


I just got back from the Rapidform Success 2011 conference in Denver where I completed the Rapidform Advanced XOR training - great experience, learned a lot. I was impressed with the software before and I’m even more impressed now.

Rapidform XOR is software for processing 3D scan data. Rapidform uses the Parasolid modeling kernel and creates parametric solid CAD models. The modeling tools are comparable to the major CAD packages plus the software has great tools for processing scan data.

I’m looking forward to applying what I’ve learned...