Case Study Portfolio by svo89594

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									                              GKS Inspection Services
                              25 Years of Successful 3D Laser Scanning Projects Across the Globe


                              measure@gks.com | GKS.com


       Case Study Portfolio 
With 25 years of successful 3D laser scanning projects across the globe
we can help with your reverse engineering and inspection needs.

Our long list of customers large and small include leading U.S. and
international manufacturers of electronic devices, cellular phones,
plastics, automobiles, medical devices, testing equipment, electrical
equipment, aerospace equipment, and numerous educational institutions,
art and natural history museums, as well as government agencies.

Check out a few of our case studies and contact us at measure@gks.com
when you’re ready to begin your project!



     GKS has been satisfying customers from around the globe for 25 years— big or small 




                         www.GKS.com | measure@gks.com | 952‐884‐9648 
                                  GKS Inspection Services
                                  25 Years of Successful 3D Laser Scanning Projects Across the Globe


                                  measure@gks.com | GKS.com




                            3M Design Corrected Mid‐Project 

The need for safety & protection of people    to directly cut the face shield molds.
working in facilities is increasing, which
                                              “We definitely cut our time and costs,”
prompted 3M’s Occupational Health and
                                              commented 3M. “The traditional trial-and-
Environmental Safety division to develop a
                                              error method of CAD iterations is expen-
new face shield for welders. Well into the
                                              sive. I estimate we saved from $3,000-
design process they were unhappy with
                                              $5,000 in CAD modeling time by using
the aesthetics of the design and felt the
                                              GKS Inspection Services instead.”
concept to CAD and to rapid prototypes
was not working-- a major correction to
the design was needed in the middle of
project execution.
A clay model was quickly made and
brought to GKS Inspection Services where
the left half was scanned. The resulting
point cloud was used to guide the creation
of the new surfaces in CAD and mirror
them to the other side, thus saving scan
time and insuring a balanced design. 3M
also needed 3D curves created at some of
the surface intersections and orientated to
an origin at a specified location.
Within 24 hours of contacting GKS, the
client had the CAD data of the redesigned
shield with the key points and features.
From there, the designers could finalize
the design in 3D CAD which would be used




                             www.GKS.com | measure@gks.com | 952‐884‐9648 
                                    GKS Inspection Services
                                    25 Years of Successful 3D Laser Scanning Projects Across the Globe


                                    measure@gks.com | GKS.com




                                  Scan Provides Perfect Model 
                                  for Prosthetic Fingers 
Didrick Medical, a company that designs         The accuracy of the point data
and fabricates active-function artificial       GKS provided is .002” or .05 mm
finger prostheses for partial finger            of the actual hand cast. To
amputees contacted GKS Inspection               achieve a model of free-form
Services about performing scans of two          shapes with this kind of accuracy
small hand casts for which they were            is impossible by any other
creating prosthetic devices. The devices        means. With such an accurate
are body-powered, light-weight, and allow       definition of the actual hand, the
users to regain complete control of the         company can fit a prosthetic
flexion and extension movements of an           device perfectly.
artificial finger. The owner needed 3D
digital CAD model files to create custom        The files were imported as solids
prosthetics more cost effectively for a         into SolidWorks, and the owner
larger market.                                  was able to do cross-sections and use the
                                                side views, which is essential to creating
                                                custom prosthetic finger assemblies. GKS’
The casts each took approximately one           expert metrologists made the 3D scanning
hour to scan. Compared to manually              pro-cess quick, accurate, and cost-
measuring, “the process of laser scanning       effective from start to finish, eliminating
cut 60% off the amount of time to make          completely time-consuming manual
enough accurate measurements of the             measurement. Laser scanning brings the
casts to create a CAD model,” said the          custom fabrication process for prosthetic
owner. “With over 600 different variations      fingers several steps closer to being an
of each finger-hand configuration, plus six     off-the-shelf product.
different hand sizes, getting the correct
measurements is incredibly labor
intensive. The speed and accuracy of laser
scanning allows me to standardize
assemblies and sizes and make all the
parts interchangeable. In the future, this
will reduce costs, increase availability, and
make the process easier and faster for the
benefit of the amputees.”




                              www.GKS.com | measure@gks.com | 952‐884‐9648 
                                   GKS Inspection Services
                                   25 Years of Successful 3D Laser Scanning Projects Across the Globe


                                   measure@gks.com | GKS.com


               Saving Time by Creating Ready to Use 
               Data 
Otter Products produces rugged cases for       exactly the right place. They design
electronics products, their current project    around the keypad, speaker, and
involved designing a case for a cell phone.    microphone openings, so having a precise
In order to design the case, Otter Products    3D model is essential. Non-contact laser
needed an accurate CAD model of the            scanning is perfect for this application
device.                                        because it does not distort the shape of
                                               delicate features.
The challenge in designing OEM cases is
making an extremely accurate case              GKS created a whole 3D model
quickly without having finalized CAD data.     automatically and then created a parasolid
When Otter engineers begin to design a         3D model. The advantage of parasolids is
case, the base model may exist only in         that they are continuous surfaces and
CAD and is not yet a physical part.            have no untrimmed edges, which prevent
Sometimes the item may be in the               software from working with a model.
prototype or first-run stage, so the
                                               “The data from GKS was very high quality,
dimensions are not yet hard and fast.
                                               very usable CAD, and decreased our lead
Other times the OEMs are protecting
                                               time by about a week.” said the Otter
proprietary data and release only the skin
                                               engineer. GKS 3D models are accurate to
CAD. All of these situations make it
                                               within a few thousands of an inch, saving
difficult to create a case for the product.
                                               the designers time by not having to redo
At first, Otter tried to use a desktop         projects due to errors in the prototype
scanner to make a 3D model, but quickly        phase or to do multiple design iterations.
found that the scan was of inferior quality.
The machine had no built-in logic and
no processing capability, so every
wrinkle and bump in the data was
manifest in the physical 3D model.
Otter needed a detailed rendering of
the device’s exterior skin so they could
design a shell that conformed to the
shape. Their shell must preserve full
functionality of the device, which
means that all the openings for spring-
loaded buttons, ports, connectors, the
battery case, and possibly a camera
lens and microphone must be in




                             www.GKS.com | measure@gks.com | 952‐884‐9648 
                                  GKS Inspection Services
                                  25 Years of Successful 3D Laser Scanning Projects Across the Globe


                                  measure@gks.com | GKS.com




       Correcting the Fit Between Toro’s 
       Disparate Models 
The Toro Company was in the final phase       With virtual scan data, we can overlay
of developing a new single-stage snow         one part’s data with the other’s until they
thrower when it ran into an interference      are aligned correctly in the model. After
problem between two large rotor housing       the correct alignment was achieved, GKS
components. One of the parts was made         scanned the rest of the housings, paying
of an injection molded polymer, the other     close attention to key areas. This
was stamped steel.                            technique simulates the physical assembly
                                              that occurs during manufacturing. GKS
Since both parts were already tooled, Toro
                                              then created surfaces from the data,
needed accurate inspection data that
                                              focusing especially on the critical
could be compared to existing Pro-E 3D
                                              locations.
models in order to determine where the
interferences were occurring, and how to      The scan data indicated that both parts
modify the tooling to get the parts to fit.   had significant areas contributing to the
                                              interference problem. Toro engineers
GKS Inspection Services performed three
                                              were then able to download the scan data
quick preliminary scans to determine the
                                              files directly into Pro-E, and compare the
correct shape and placement of the two
                                              results to the 3D models.
parts in relation to each other when they
were assembled. This “mock assembly           “The process was very successful for us,”
process” aligned the housing to a             concluded the Toro designer. The mating
manufacturing datum, ensuring that the        assembly holes in the initial parts were
snow thrower auger axis datum was in an       almost one-half diameter off, but by using
acceptable position with respect to the       the scan data, the engineers
rest of the housing.                          were able to correct the
                                              problem quickly and accurately
                                              before the pre-production pilot
                                              build, and more importantly,
                                              before the production process
                                              was online.




                             www.GKS.com | measure@gks.com | 952‐884‐9648 
                                    GKS Inspection Services
                                    25 Years of Successful 3D Laser Scanning Projects Across the Globe


                                    measure@gks.com | GKS.com



        Speedy Delivery for 
        Ferrari Racer 
The Austin Group was contracted to            Instead, the
reconstruct a transmission case made for      Austin Group
a rare 1967- 330P4 Ferrari Racer. The         opted to use
original P4 Racers are estimated to be        laser scanning
worth $10 million, and a replica can net      where far more points are generated, so
$200,000. The functioning transmission        the solid models are created quicker and
case consisted of complex shapes that         with better accuracy.
required high levels of accuracy, and the
                                              GKS Inspection Services provided the
customer wanted the part right away.
                                              Austin Group with laser scanning and
Computer-aided design geometry did not        consultative engineering services for both
exist for the transmission case, so the       the reverse engineering and inspection of
Austin Group needed to reverse-engineer       the part. In less than a week, GKS
the component. In the past, the design        provided solid models of the component
firm used a digitizer arm to measure the      that matched the original physical part at
position of individual points as it was       40% less and twice as fast.
moved around a part. The resulting points
                                              With the geometry of the Ferrari Racer
were imported into modeling software for
                                              transmission case fully defined, they could
the designer to stitch together to form a
                                              proceed with casting it in lost foam. Using
solid model of the component.
                                              the solid model provided by GKS, the firm
Generally, capturing a few thousand           created a foam pattern and gating system,
points with the digitizer arm would take      which was coated with refractory and
70 hours, but many of the points needed       dried under controlled conditions. The
to determine the precise geometry of a        coated cluster was invested in a flask with
component often still are missing. The        loose, unbonded sand, which then was
designer is forced to rely upon intuition     vibrated for compaction. Molten metal was
and guesswork to create a final model.        poured onto the top of the gating system,
The interpretation process typically takes    directing the metal throughout the cluster
50 hours of work, making the total time       to replace the foam gating and patterns
spent to re-engineer the part 120 hours.      and create the casting.




                              www.GKS.com | measure@gks.com | 952‐884‐9648 
                                  GKS Inspection Services
                                  25 Years of Successful 3D Laser Scanning Projects Across the Globe


                                  measure@gks.com | GKS.com



         About GKS Inspection 
               Services 
For over 25 years GKS Inspection Services has been the standard of
excellence for ultra-precise, 3D laser scanning used for reverse engineering
and inspection. We have locations around the globe including a Plymouth, MI
lab which is accredited by the A2LA for Mechanical Testing and Calibration.
We can scan everything from small, highly detailed parts to entire vehicles and even
buildings and ships.
3D laser scanning is a non-contact technology that digitally captures the shape of
physical objects using laser light. We measure fine details and capture complex
geometries with an accuracy of ±.0005", to quickly generate a highly accurate
surface model that represents the original design.
Benefits of laser scanning with GKS:

•   Laser scanning is fast and accurate, reducing time to market

•  Laser scanning measures the entire surface of your object, improving inspection
and verification, and reducing the discrepancy between the as-designed part and the
as-built part

•   Laser scanning allows you to create true CAD models.

•   Laser scanning can be used to validate, even when no CAD model exists
Whether comparing a physical part to its CAD model or digitizing a prototype with the
intent of developing a new CAD model, GKS laser scanning yields high accuracy point
cloud data that can be modeled and used for many purposes.
The assurance of knowing your part is created to its design intent gives you a
competitive advantage—GKS provides fast and accurate 3D solutions. Projects can be
ready in as little as 2-3 days and even as quickly as overnight with guaranteed
results. For info: measure@gks.com and visit us at GKS.com




                            www.GKS.com | measure@gks.com | 952‐884‐9648 

								
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