A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

2014 Q-PLUS Labs. All rights reserved.

A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

A MULTI-DIMENSIONAL LOOK AT 3D SCANNING:

WHEN, WHY, AND HOW TO USE IT
INTRODUCTION .
WHAT IS 3D SCANNING?
CONTACT SCANNERS
Coordinate Measuring Machines
Articulating Arms
Form and Contour Tracers ...
NON-CONTACT SCANNERS ...
3D Laser Triangulation ......
White Light Scanners ....
Conoscopic Holography ......
Time-of-Flight and LiDAR ....
Photogrammetry ......
CT Scanning and MRI
FOR VERY SMALL OBJECTS .
Laser-Scanning Confocal Microscopes
White Light Interferometry
Axial Chromatism
WHEN SHOULD YOU USE 3D SCANNING?
REVERSE ENGINEERING
FIRST ARTICLE INSPECTION
QUALITY CONTROL INSPECTION (PROCESS CONTROL)
ANALYSIS ...
DOCUMENTATION
WHY SHOULD YOU USE 3D SCANNING?
Speed ..
Coverage .
Accuracy .
Cost .
SHOULD YOU PURCHASE EQUIPMENT OR OUTSOURCE?
HOW OFTEN DO YOU NEED TO SCAN? ...
HOW QUICKLY DO YOU NEED RESULTS? ..
WHAT IS YOUR BUDGET?
HOW MANY TYPES OF OBJECTS DO YOU NEED TO SCAN?
DO YOU HAVE IN-HOUSE EXPERTISE? ..
CAN YOU MEET THE NECESSARY ACCURACY REQUIREMENTS? .
HOW DO YOU DETERMINE WHICH 3D SCANNER TO USE? ...
Surface characteristics
Object size
Object shape
Accuracy
Speed .
Cost
COMMON 3D SCANNING MYTHS DISPELLED
MYTH: NOT ENOUGH ACCURACY .
MYTH: THE TECHNOLOGY IS UNPROVEN ..
CONCLUSION

2014 Q-PLUS Labs. All rights reserved.

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A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

Introduction
3D scanning is a growing
sub-field of measurement
that includes many types of
scanning devices for a
broad range of
applications. Although it is
relatively new on the
scene, 3D scanning is
widely accepted as an
effective, accurate, and
fast way to collect and analyze measurement data. In fact, the level of detail that 3D
scanning can capture makes it the method of choice for many applications.
This guide will cover the basics behind the technology using a traditional informationgathering technique:
What A description of the technology and the types of 3D scanning available
When The most common applications for 3D scanning
Why Advantages of using 3D scanning over other methods
Who Factors to help you decide whether to outsource or purchase
equipment
How Tips for deciding which 3D scanning technology to use

We will also dispel some common myths related to 3D scanning so you can embrace
this technology with confidence.

What Is 3D Scanning?
In general terms, 3D scanning involves the collection of dimensional coordinate data
about the shape and size of an object. After the data is collected, it is processed using
point cloud software that can be used in a number of ways. With reverse engineering,
a digital 3D model can be generated from the data and used for a range of
applications. With dimensional inspection, the data can be compared to an existing
2014 Q-PLUS Labs. All rights reserved.

A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

design or analyzed for other applications.

The data collection phase requires a scanning device that gathers measurement
information about the features of an object. The characteristics of the object inform
which type of scanning technology can and should be used. Depending on its shape,
size, and surface characteristics, one of the following types of 3D scanning methods
may be employed. Although this is not an exhaustive list, it is a good overview of the
types of scanners and technology you are likely to encounter:

Contact Scanners
One method for collecting measurement data involves physically scanning the object
with a device that comes into contact with every point on the surface. Contact
scanners are available in multiple types that can be used for various applications.
Coordinate Measuring Machines
Coordinate Measuring Machines (CMMs) are mechanical systems that use a
measuring probe and transducer technology to convert physical measurements
of an objects surface into electrical signals that are then analyzed by
specialized metrology software. There are many different types of CMMs; the
most basic systems use hard probes and XYZ read-outs, while the most
complex employ fully automated continuous contact probing.
Articulating Arms
An articulating arm is a type of CMM that
uses rotary encoders on multiple rotation
axes instead of linear scales to determine
the position of the probe. These manual
systems are not automated, but they are
portable and can reach around or into
objects in a way that cannot be
accomplished with a conventional CMM.

2014 Q-PLUS Labs. All rights reserved.

A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

Portable Optical CMM

Some applications call for a portable solution, for example, taking
measurements on a shop floor or in the field. In these cases a portable CMM
can be used to gather measurement data for areas that are difficult to reach.
The hand-held device transmits data wirelessly and allows the operator to move
both the part and the scanner during the measuring process.
Form and Contour Tracers
Form and contour tracers are purpose-specific devices that use extremely
accurate continuous contact sensors and styli to obtain small-part geometry.
These devices are especially useful for scanning objects that include threaded,
cylindrical, or round features.

Non-Contact Scanners
The main reason to utilize non-contact
scanners is immense amounts of data
that can be collected quickly. Also, in
many cases, using a contact sensor is
not appropriate because the act of
touching the object during measurement
will alter its geometry, thus creating an
inaccurate 3D model. Objects that are
fragile, flexible, or otherwise sensitive are
more suitable for the following types of
3D scanning technologies:
3D Laser Triangulation
With this type of 3D scanning system, a laser is projected onto the surface of an
object and a camera captures the reflection. The laser can be in the form of a
single point, a line, or an entire field of view. When the reflection is captured,
each point is triangulated, measured, and recorded, resulting in a 3D rendering
of the shape and surface measurements of the object. Laser scanning tends to
work better with more reflective surfaces than structured light scanners.

2014 Q-PLUS Labs. All rights reserved.

A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

White Light Scanners

White light scanners, also referred to as structured light scanners, use halogen
or LED lights to project a pattern of pixels onto an object. The distortion of the
pixels created by the objects surface and the resulting light pattern can be
measured and used to reconstruct a 3D image. Such scanners also may use
other colors of the light spectrum such as blue or red light though the effect or
improvement in results is small.
Conoscopic Holography
Another type of 3D laser scanning technology is conoscopic holography. A
single laser is projected onto the object, and the reflection is returned along the
same path. The reflected beam goes through a conoscopic crystal and is
projected onto a charge-coupled device (CCD). The diffraction pattern is then
analyzed to determine the precise distance to the surface. The most common
applications for this type of device are measuring small features as well as
interior surface geometry where triangulation would not be possible. It is highly
precise and commonly found on multi-sensor vision systems. This technology
works fairly well despite surfaces that are highly reflective or absorbent.
Time-of-Flight and LiDAR
This type of laser scanning uses a time-of-flight
laser rangefinder based on LiDAR technology to
measure the distance between the laser and the
objects surface. The laser rangefinder sends a
pulse of light to the object and measures the
amount of time it takes for the reflection to return
in order to calculate the distance of each point
on the surface.
Point measurements are taken by aiming the
device at the object and using a series of mirrors
to redirect the light from the laser to different
areas on the object. Although the process may
seem cumbersome, typical time-of-flight 3D

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A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

laser scanners can collect between 10,000 and 100,000 points per second,
which is much faster though less accurate than contact sensors.
Photogrammetry
Perhaps the oldest type of non-contact 3D scanning method, photogrammetry
has been in use since the development of photography. In simple terms,
measurements between two points on an image can be used to determine the
distance between two points on an object. Several factors play a role in the
accuracy of this type of system, including knowledge of the scale of the image,
the focal length of the lens, orientation of the camera, and lens distortions.
Photogrammetry can be used to measure discrete points using retro reflective
markers which can be highly accurate given the measurement envelope. More
recently, photogrammetry coupled with special image processing software can
be used to obtain complete and dense point clouds. These point clouds are
typically less accurate than other forms of scanning, however only a camera and
software is required making it one of the lowest cost methods of 3D scanning.
Photogrammetry is also often used in combination with other types of 3D
scanning technologies that produce point cloud results, primarily to increase the
measurement range by creating a reference frame of discrete points on which to
match multiple 3D scans.
Lastly, one particularly interesting feature of photogrammetry is that the
measurement envelope is virtually limitless.
CT Scanning and MRI
Magnetic resonance imaging (MRI)
and computed tomography (CT)
scanning are generally known for their
medical applications, but they can
also be used for 3D scanning in
metrology. CT scans use x-rays to
detect and display both the internal
and external geometry of an object.

2014 Q-PLUS Labs. All rights reserved.

A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

MRI scans use nuclear magnetic resonance to do the same.

The two types of scanning devices have different capabilities with respect to the
density of objects. MRI scans are generally better for objects that are made from
softer materials, whereas CT scans are more suitable for objects that are more
rigid and made of harder materials. Objects that are made from materials that
contain no water are not suitable for MRI scanning. However, when either MRI
or CT scanning is possible, MRI often produces more detailed results that can
be refined by adjusting the radio frequency and magnetic fields while
scanning. One main advantage of these types of scanning systems is the ability
to collect data about the internal geometry of the part without destroying or
damaging it.

For Very Small Objects

In addition to the form and contour tracers that use contact sensors, small objects can
also be scanned with non-contact methods.
Laser-Scanning Confocal Microscopes
A confocal microscope uses a process called optical sectioning to collect images
from various depths. These images can be reconstructed with a computer to
create a 3D model of complex small objects. Unlike other laser systems, a
confocal microscope only sees one depth level at a time, which allows it to
generate a highly controlled depth of focus for very small objects with tight
tolerances.
White Light Interferometry
This non-contact measurement system allows you to obtain surface
measurements at the micrometer level. The technology behind white light
interferometry uses wave superposition to measure distances based on data
collected about reflected wave interactions.
Interferometers can also be combined with microscopes to measure very small
objects. Because they rely on the detection of waves and not optical images,
interferometers are also useful for measuring objects with reflective surfaces.

2014 Q-PLUS Labs. All rights reserved.

A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

This technology is limited in terms of the angle of surface that can be measured
but for what it can detect, it is virtually unbeatable in accuracy.
Axial Chromatism
Like interferometry, axial chromatism
also uses white light to collect
measurement data. However,
whereas interferometry uses the
superposition of waves after they are
reflected off the object, axial
chromatism measures the wavelength
as it hits the surface of the object.
This method produces more reliable
results when measuring surface
roughness or step-height depth, due
to the minimum mathematical
calculation required.
The tolerances of large objects may allow the use of a thin whitening spray to
facilitate scanning but the geometry of very small objects could be potentially
buried by it. Fortunately, all of these methods work well with various types of
surfaces from reflective to absorbent.

When Should You Use 3D Scanning?

3D scanning can be used for a broad range of applications, but it offers the most
benefit for the measurement of objects with non-prismatic geometry. Other methods
typically require data extrapolation or exclusion, but 3D scanning allows you to capture
significantly more data points over the entire surface of the object.

2014 Q-PLUS Labs. All rights reserved.

A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

Reverse Engineering
Reverse engineering is the process of
evaluating an object to better understand
how it functions or to have the ability to
replicate it. The challenge in reverse
engineering a physical object lies not
only in determining how it was made with
little or no knowledge of the original
production process but in accurately
determining what its geometry is.
Examples of reverse engineering applications include:

Artifacts for replication with a 3D printer

Car floor contouring for production of molded mats
Teeth for artificial replacements
Replacement parts for manufacturing processes
Replacement parts for aircraft

Regardless of the application, the first step in reverse engineering is creating an

accurate 3D CAD model of the original object and/or an engineering drawing. 3D
scanning is one of the fastest, most accurate methods for creating 3D digital models,
especially for objects with irregular geometry.

First Article Inspection

The manufacturing industry relies on
first article inspection to measure
parts, verify engineering
specifications, and refine
manufacturing processes. 3D
scanners can be used to create a full
point cloud dataset of the first article

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A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

produced on a manufacturing line for comparison to the engineering digital model

and/or drawings. Process modifications can be made based on the deviations
between the first article and the drawings.
Often, time is of the essence when a manufacturer develops a new product, which is
why 3D scanning can be so useful for this type of application. The results are
accurate, and with advance preparation, turnaround time can be fast relative to other
technologies. Post- processing of 3D scan data can be programmed in advance of
production so once the full dataset is obtained the part can move on to the next
operation and the scanner can move on to the next part with measurement results
computed in as little as a few seconds.

Quality Control Inspection (Process Control)

Parts on a production line must be periodically inspected to ensure that they continue
to meet specifications, and to confirm that the manufacturing process is operating as
expected. 3D scanning can be used for off-site testing in a specially equipped
metrology lab; it can also be integrated directly into a manufacturing line to speed up
the quality control process.

Analysis
3D scanning is just a method for collecting information about an object. What can be
done with that information is at the users discretion. Uses for the data captured with a
3D scanner include:
Comparing the profile of objects by color mapping
In depth blue-printing of geometry
Compensatory process control
Analyzing the aerodynamics of an object
Evaluating the potential causes of an automobile collision
With point cloud data and a 3D model, you can use a range of techniques and
software programs to analyze an objects shape and various other dimensional
characteristics.

2014 Q-PLUS Labs. All rights reserved.

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A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

Documentation
3D scanning can capture and document the
state of an object for future reference.
Perhaps you want to create a 3D model of
a series of prototype parts so you will have
a record of each version used in an
experiment. Perhaps a tooling die had to
undergo numerous manual modifications to
correctly produce a part and the specific
changes need to be collected for use in
making the next die. An archaeologist
might want to capture every contour of an
artifact for historical documentation.
Regardless of the application, 3D scanning
gives you the ability to capture the shape of
an object in a digital format that can be
used indefinitely, no matter what happens to
the original object.

Why Should You Use 3D Scanning?

3D non-contact scanners are faster, and therefore potentially more cost-effective than
other metrology techniques such as a CMM. Advances in both scanning technology
and point cloud data processing are bringing 3D scanning to the forefront of
metrology.
Some of the advantages of using 3D scanning over other types of technologies
include:

2014 Q-PLUS Labs. All rights reserved.

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A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

Speed
Automated 3D scanners can measure thousands of points per second, which is
much faster than manual measurement devices.
Coverage
3D scanners are able to collect and measure millions of data points on the
surface of an object, often in a matter of minutesan achievement that was
neither practical nor possible before the technology was developed.
Accuracy
Strides in 3D scanning technology have continually improved the accuracy,
making it an increasingly formidable measure measurement method. The level
of detail you can capture has improved significantly as the ability to gather more
data points has increased.
Cost
3D scanning is a cost-effective measurement solution compared with alternative
technologies, especially when you factor in its relative speed and ease of data
acquisition.
Of course, 3D scanning is not appropriate for every measurement application. If you
need to measure only one dimension or if the object has extensive interior surfaces or
if the tolerances are very tight, a different approach might make more sense.

Should You Purchase Equipment or Outsource?

If you determine that 3D scanning is the right choice for your application, you must
decide whether to purchase equipment for in-house use or outsource scanning
services to a qualified provider. Several factors play a role in this decision,
including:

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A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

How often do you need to scan?

If you perform regular real-time in-process
quality control checks, on-site equipment is
imperative. However, if you need first article
inspections of complex parts or periodic inprocess measurements, working with an
outside measurement lab can save you time
and money. You wont have to worry about
maintaining equipment or hiring qualified
staff, and you have more control over the costs.

How quickly do you need results?

Instant measurement results likely necessitate having your own equipment, especially
if you have the resources to support it. However, a qualified lab can also produce fast
results, especially if you work closely together from the beginning of the project.
Measurement programs can often be generated in advance of the arrival of the
part.

What is your budget?

Before purchasing a new system, be sure to factor in the lifetime costs of equipment,
training, and maintenance. If you expect to regularly use the equipment for a long
period of time, purchasing may be the most cost-effective solution. However, if you are
uncertain about whether you will need 3D scanning capability in the long term, starting
with outsourcing is prudent. Another factor to consider is evolving technology. One of
the benefits of working with good outsourcers is that they stay on the cutting edge,
purchase the latest equipment, and learn the newest techniques.

How many types of objects do you need to scan?

If you know that you will only ever need to measure one type of object that is the same
size and has the same types of surface characteristics, you can purchase a device

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A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

with confidence. However, if you are not sure how your measurement needs will
change over time, outsourcing is perhaps a better solution.

Do you have in-house expertise?

Most 3D scanning equipment requires a
level of training that your staff may not
possess. Of course, you can hire
qualified operators or train your existing
staff, but this requires an investment that
can also take some time. Outsourcing to
a metrology lab will allow you to dedicate
your personnel resources where they are
best suited, thus leaving the scanning
requirements to the experts.

Can you meet the necessary accuracy requirements?

Depending on your industry and application, NIST traceability and other regulatory
requirements may be necessary. If this is the case, you must ensure that both your
equipment and processes are in compliance. If you are not confident that these
requirements can be met in-house, outsourcing to an expert is wise.

How Do You Determine Which 3D Scanner to Use?

Different objects require different types of 3D scanners, and several factors play a role
in determining which type of system to use. Whether you decide to purchase your own
equipment or outsource, you will need to determine which type of scanning method
makes the most sense for your application.
Using a 3D scanner to create a model for replication of a childrens toy is completely
different from using the same technology in the aerospace industry. The details of
your specific project will inform which type of technology is most appropriate.

2014 Q-PLUS Labs. All rights reserved.

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A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

Consider the following factors when making your decision:

Surface characteristics
Is the object shiny, smooth, rough, dark, pitted,
or soft? Each type of 3D scanning technology
brings its own strengths and weaknesses to
different types of surface characteristics.
Understanding which type of system will work
best with your object is the first step to
selecting a 3D scanning method.
Object size
3D scanning can be used to measure objects from the nano level to entire
buildings, and everything in between. Naturally, no single piece of equipment
can cover this entire range.
Object shape
Although 3D scanning is generally recommended for objects with non-prismatic
geometry, there are still factors within that classification that play a role in
determining which type of scanning technology to use. For example, an object
with deep boreholes may require a touch probe in combination with laser
triangulation.
Accuracy
Reverse engineering a precision part or scanning an object for medical use
requires a higher degree of accuracy than replicating a souvenir. Factors such
as NIST traceability and the end application can help you determine which type
of 3D scanning equipment to select.
Speed
Some 3D scanning equipment produces faster results than others. In general,
speed is related to accuracy, so if you do need a high degree of accuracy, the
job will likely take longer. However, if you are using 3D scanning for first article

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A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

inspection and need quick results, you may be able to select a solution that
meets your requirements for both speed and accuracy.
Cost
Every business operates with a budget. Accuracy and speed generally come
with a higher price tag, so carefully consider your needs before making an
investment.
If you do not have expertise in 3D scanning, work with a qualified professional to help
you select the right equipment for your application. Producing useless results that
dont meet your accuracy requirements is a waste of time and money, and breaking
the bank for a level of accuracy and detail that you dont need wont make sense,
either.

Common 3D Scanning Myths Dispelled

Because 3D scanning is still a relatively new technology in the field of metrology, there
are some common myths and misconceptions about it. Understanding the truth behind
these myths is important for ensuring the success of your project.

Myth: Not Enough Accuracy

The reality is that metrology-class devices do exist. If NIST traceability is important to
you, 3D scanning is still very much a possibility, provided you work with the
appropriate equipment and a provider that can go over the various system accuracy
statements, and provide validation as well as gage repeatability and reproducibility
tests.
The basis of 3D scanning technology is the collection of data points. The more data
points the equipment is able to collect, the higher the resolution you will be able to
achieve. Accuracy also depends on many other factors such as camera quality and
correct calibration. Although not all 3D scanning tools will produce results with the
level of accuracy you need, chances are there is a solution that meets your
requirements.

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A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

Myth: The Technology Is Unproven

The truth is that a good provider can use multiple techniques to prove out accuracy
and demonstrate that the 3D scanning results are correct. Just because there is not
yet a formal American or International Standard for determining the accuracy of a 3D
scanner does not mean the accuracy of a scanner cannot be determined. In some
cases, 3D scanning may be just one component of the overall measurement
approach.
3D scanning technology has been proven to be a valid measurement tool, but
working with trained professionals and properly calibrated equipment is essential to
ensure accurate results. Remember, there is no one-size-fits all solution for 3D
scanning. Selecting the right equipment for your application is critical for success.

Conclusion
3D scanning is an increasingly proven
technology that is here to stay. New
technological strides are achieved on an
ongoing basis, making it even more
accessible and reliable. Whether your
project entails reverse engineering, first
article inspection, object replication, or
documentation, there likely is a 3D
scanning solution that will meet your
needs.
When determining what 3D scanning approach to take, base your decision primarily
on these three straightforward factors:
Accuracy
Speed
Cost

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A Multi-Dimensional Look At 3D Scanning: When, Why, And How To Use It

Understanding the specific requirements of your application and the limitations of

your equipment is the first step to ensuring success.
Whether you decide to purchase your own equipment or outsource 3D scanning
services, Q-PLUS has the latest available technology and the skills to help you
successfully navigate your project. We are an authorized reseller for dozens of
manufacturers, and because we use the same equipment every day in our own labs,
we are uniquely qualified to help you select the appropriate solution. Should you
decide to outsource services, well work with you from the beginning to ensure that
we thoroughly understand your needs and can help you achieve your goals in the
most cost-effective manner.
Contact Q-PLUS Labs today for a consultation and a free quote. We work in a broad
range of industries including aerospace, medical, archaeological, precision
manufacturing, and more.

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