3-D Printing & Scanning In Construction

Transcription

1 3-D Printing & Scanning In Construction Presented by: Christopher Dabek Freedom Cement LLC Cody Ivers Freedom Cement LLC

2 3-D Scanning Lightweight, handheld scanner Scan pre-existing structures Faster repair time Scan-to-model in minutes, not hours Requires trained operator High accuracy, high resolution 0.040mm ( ), 0.100mm ( ) Handyscan 300 by Creaform. Using our 3-D scanner, we can scan original stones with any defects and remodel them to their desired geometry. Once remodeled, we can then 3-D print patterns or fixtures for molding purposes.

3 3-D Printing Replicate units full scale. Create scale models. Tools, sections, and profiles for pattern making. Cuts down man hours. Little to no post processing required. High resolution mm (0.005in) Large Build Volume. (16 x 14 x 16 ) Fortus 450mc FDM 3-D printer by Stratasys.

4 Historic Baluster Replication Original baluster to be corrected. The baluster is reproduced using dimensions taken from scan data. 3-D mesh of baluster unit in VXelements software.

5 Historic Baluster Replication 1:1 scale 3-D printed mid section after removal from printer. Rebuilt baluster unit in Solidworks using correct dimensions. 1:1 scale 3-D printed baluster with correct geometry.

6 Historic Baluster Replication Coated 3-D printed top section. Coated 3-D printed mid section. Coated 3-D printed bottom section. 1:1 scale 3-D printed baluster coated in texture paint.

7 Historic Baluster Replication Two part molds were used for each of the three sections. The molds are painted first with the desired gel coat color, then the material is poured into the mold. The two parts were held together with a wooden box, leaving one exposed opening for pouring. Microcotta being poured into a two part mold of the baluster mid section. Two part mold of the baluster bottom section. Two part mold of the baluster bottom section with gel coat. Baluster mid section two part mold.

8 Historic Baluster Replication Finished replicated baluster sections during assembly. Finished replicated baluster ready for shipping. Original baluster (left) and replicated baluster (right.)

9 Historic Bracket Replication Original terracotta unit on building before scan. Original terracotta unit after demo. Original terracotta unit after demo.

10 Historic Bracket Replication Top section of scan mesh in VXelements software. Bottom section of scan mesh in VXelements software. Rebuilt unit in Solidworks

11 Historic Bracket Replication 3-D printed part used for mold making. Cast unit curing in mold. Cast unit ready for finishing.

12 Replicating a Historic Capitol Multiple existing units scanned to collect missing data. Scan data converted to 3-D mesh automatically. Mesh reviewed by operator during scanning to ensure proper data collection. Units delivered to our shop on a USB stick, not a flat bed. This capitol was originally made of terracotta, deteriorating over time despite patch attempts. Original terracotta capitol to be corrected.

13 Data Acquisition Original terracotta capitol being scanned from scaffolding. Original units can be scanned with scaffolding access. Approx mins. per scan. (time varies with computer specs.) Reflective targets are placed on the units for scanner positioning. Multiple damaged units can be scanned to digitally create one whole intact unit.

14 Data Acquisition Reflective, contoured targets are placed on the unit for scanner positioning. Scanner must be able to see 3 targets min. to begin acquiring data. Scan area around unit being replaced to ensure proper fitment during reproduction. Data is shown in the scan software in real time. Operator can digitally zoom on the unit to spot areas that might have been missed. Rebuilt capitol in VXelements software by Creaform.

15 Digital Repairs Using the scanner software, the capitol scans were cut into sections based on what was usable from each unit. The scans were then merged together to create one complete unit. The 3-D mesh was then cleaned off an defects before converting to a solid model. The part is then measured within the scan software. Measurements can be used for reference while rebuilding the unit. Rebuilt capitol in VXelements software by Creaform.

16 Scan-to-CAD Using derived dimensions from the 3-D mesh, the capitol is then rebuilt using a combination of Solidworks surfacing techniques and existing part geometry. Cross sections, planes, and other geometry derived from the scan were used to rebuild the capitol. Rebuilt surfaces and existing surfaces can be combined during reconstruction to avoid rebuilding the entire stone. After rebuilding the model, the model was then divided into eight sections for printing. The sections were then bonded together. Rebuilt capitol in Solidworks 2017

17 3D Printed Model The master pattern was created by utilizing a FDM 3D printer. Eight sections were printed and bonded together using plastic welding. The printed model was then hand sanded to remove any defects before molding. 3-D printed parts are bonded together to create whole units

18 Bonding Printed Parts #1 #2 Software automatically generates registration features for bonding. Registration features allow the parts to interlock. #3 #4 The parts can be bonding using plastic welding or adhesive. Hand sanding and an acetone spray help blend the surfaces.

19 3D Printed Model Full scale capitol 3-D printed. Test fitting the 3-D printed model.

20 Finished Product Capitols being finished before packaging. Replicated capitols on the First Baptist Church in Pittsfield, MA.

21 Replicating a Historic Angel Unit arrived broken into multiple sections. The unit was repaired prior to scanning. Scan data was used to document the unit and create shop drawings. Scan data allows for precise measurements from any two points. Original terracotta angel to be reconstructed.

22 Mu coll Sca aut Mes scan coll Uni stic Thi terr des Unit Repair Original terracotta angel to be reconstructed. Original terracotta angel during reconstruction.

23 Data Acquisition Scan data previewed in Vxelements software. Scan data previewed in Vxelements software. Mesh converted to a 3-D model within Solidworks.

24 Finished Product Mold of the terracotta angel. Replicated cast angel unit.

25 Opposite Hand Units Original terracotta railing unit on building before scan. Scanned mesh data of railing unit. Opposite hand unit created by mirroring scanned data. Cast units right (top) and left (bottom) ready for finishing.

26 3-D Printed Scale Models During the reconstruction of the model, a smaller 1:10 scale baluster was printed to ensure their were no defects in the model. This 1:10 scale portico assembly model with 16 parts was used to check for any fitment issues between the existing steel and the new cast stone pieces before production. 1:10 scale 3-D printed baluster model 1:10 scale 3-D printed assembly model made up of 16 parts. Using a to-scale steel frame model to check for fitment issue.

27 3-D Printed Scale Models

28 Christopher Dabek Freedom Cement LLC Cody Ivers Freedom Cement LLC Represented by: ConSpec Associates Inc.