See Beyond the Surface. CT Scanning Redefining Industrial Metrology

Transcription

1 See Beyond the Surface CT Scanning Redefining Industrial Metrology

2 Table of Contents Table of Contents 1. What is Computed Tomography (CT) Scanning? 2. How CT Scanning Works 3. Advantages of CT Scanning 4. When to Use CT Scanning 5. Who is 3DProScan? 6. What Our Customers Think

3 What is CT Scanning? Along with the development of software technology (new software innovations promise greater accuracy and speed when measuring and analyzing parts), CT scanning is the most advanced measurement technology available to us today. CT scanning, also known as three-dimensional (3D) x-ray computed tomography or metrotomography, captures data at an accuracy of 5-7 microns and scans an article in an hour. For these reasons, CT scanning is fast becoming important to industrial metrology equipment manufacturers. Device manufacturers realize that the same technology used to scan people for medical conditions can scan their parts and assemblies. What better way to inspect a complex assembly than by using x- ray vision to do all of the work? Just as in a hospital setting, x-rays are directed at parts or assemblies to capture images of all internal and external components. These two-dimensional (2D) images are captured virtually by a detector. A computer linked to the detector calculates volume and distances. Finally, thousands of 2D images are virtually combined to create a 3D generated model of the part that was scanned. Through continuing innovation, CT scanning is redefining industrial metrology

4 How it Works The article is placed in a machine on a custom made expanded polystyrene fixture. The machine rotates the article 360 stopping every 1/3 to capture an image images are collected in total and then constructed into a precise 3D model representation. Full scanning time can range from 45 minutes to 1 hour. Multiple smaller parts can be scanned at once. Scanning envelope of a 4.9 Dia x 4.9 Tall Cylinder

5 What are the Advantages A major benefit to CT Scanning is speed of product qualification. A whole part analysis can be done in an hour, leading to faster decisionmaking, rapid metrology and product validation. In contrast, typical scanning techniques may be destructive when determining what is happening within complex parts. With 3D scanning, virtual cross sectioning allows analysis of internal features without physical damage. An added benefit is that no fixturing is required with CT scanning. Three-dimensional (3D) scanning detects areas of poor product performance, captures data quickly, shortens production cycles and improves product design and quality. The competitive nature of the industrial marketplace drives the need to reduce costs, introduce products faster and increase longterm efficiencies. Advanced 3D CT scanning optimizes product quality, leads to quicker product launches and even recoups enormous research and development costs. Extremely Fast Dimensional inspection programs run in less than 10 minutes once the program is completed. Allows for Parallel Efforts Pre-programming can be done without plastic parts. As Capable as Coordinate Measuring Machines (CMM) All geometric dimensioning and tolerancing (GD&T) can be measured. Uses the same measurement software as high-end CMM. Accuracy is within 5 to 7 microns. Near-Perfect Inspection Technology For low-density materials such as plastics.

6 Advantages Summary Whole Part Analysis in 1 Hour - Capable of providing complete data across all dimensions. Faster Decision Making - Faster results lead to better decisions. Faster Metrology - Inspection time for CT scanning is typically hours versus days for traditional metrology techniques. Faster Validation - Reduces risk of running invalidated molds. Non Destructive Analysis - Internal complex part features and assemblies can be analyzed in a non destructive manner. No Fixturing Required - Expanded polystyrene provides for free state analysis.

7 INSERT IMAGES Cap$on and Photo Credit: Use this space to provide credit to the original photo or graphic creator and provide context on its meaning. When it comes to manufacturing, a company s needs extend beyond just metrology. We want our customers to have the best experience possible as they are qualifying their parts for production. - Visent Avxhi, Business Development Manager, 3DProScan

8 What are the Advantages? FASTscan Our integrated viewers provide the optimum tool for engineers and quality control experts. We understand the urgency with which our clients are faced with and we do our absolute best to meet their expectations. CT Scanned 3D Generation Original CAD Model

9 What are the Advantages? FASTscan Part-to-CAD Overlay FASTscans provide a comparative analysis from the original CAD model to the scanned part. In less than a couple hours, we can create a color-coded geometric comparison and provide data on the dimensional accuracy of the entire part.

10 What are the Advantages? FASTscan Part-to-CAD Overlay The FASTscan overlay is much easier to interpret than the traditional spreadsheet. A color chart on the right side of the viewer lets us know that green is nominal, red/pink is extra material or warp in the positive direction and blue/purple is less material or warp in the negative direction. Traditional Metrology Report

11 What are the Advantages? FASTscan Summary Fast Results - Complete visual analysis within hours. Dimensional Inspec$on Assessment - Predict and assure readiness for successful product inspec<on. User Friendly Viewers - Easy to use viewer that can be shared with customer, allowing analysis of overlay. Accurate micron ( ) accuracy. All dimensions and features can be viewed. Mul$ple Parts - With a scanning envelope of a 4.9 Dia x 4.9 Tall Cylinder, mul<ple smaller parts can be scanned at once.

12 What are the Advantages? Part-to-Part With a visual analysis, differences between two parts become clear and easy to understand. Using CT scanning, two parts can be scanned to generate 3D point clouds which can be overlaid to create a comparative color-coded 3D image outlining any differences and dimensional deviations between the parts. Below the part-to-part analysis can be easily seen, as green indicates nominal, red indicates extra material or warp in the positive direction and blue or purple indicates less material or warp in the negative direction. On the left, we set a tolerance of +/- 254 microns or.01. On the right, we set a tolerance of +/- 127 microns or.005. Using a color-coded map, our viewer clearly displays the differences between the two parts. Part-to-Part Overlay

13 What are the Advantages? Part-to-Part Fast Results - Complete visual analysis within hours. Accurate - 100% Representation. All dimensions and features can be viewed. Faster Toolwork Validation Using part-to-part analysis, production parts can be compared to existing gold parts with an hour. Reduces risk of running invalidated. User Friendly Viewers Easy to use viewer that can be shared with customer. When testing these two caps, we noticed that one was working properly and one wasn t. Using CT scanning, we scanned these two caps and virtually overlaid the 3D point clouds to see the dimensional differences.

14 Multiple Applications

15 Assembly Analysis We received two foam pumps. One was working properly; the other was not. With CT scanning, the two foam pumps were easily analyzed for defects. Below we can see two different cross sections of the two different foam pumps. Good Pump Defective Pump

16 Assembly Analysis The foam pump on the left worked perfectly, but the foam pump on the right had a defect at the base of the neck. In an hour we were able to analyze the problem quickly and effectively. Internal assembly discrepancies, sometimes impossible to spot with traditional inspection methods, are easily discovered using x-ray vision. Good Pump Defective Pump Void Analysis

17 Reverse Engineering Reverse engineer parts quickly and efficiently with industrial CT scanning. With CT scanning, in one hour we will accurately scan a part in it s free state and create an accurate 3D point cloud representation. The point cloud from the 3D CT scan can then be converted to an STL data file to be used for generating a CAD model. Once an STL file is available, a reverse engineering team can convert it to a new accurate CAD model of the desired format.

18 When to use CT Scanning If our customers need a formal dimensional inspection, we will inspect a part for them in less than half the time it would take with any other method. We are able to program for a first dimensional inspection using a 2D drawing and CAD model before we have the part in hand. Therefore, we can program ahead of time before we receive the part. Once we receive the part and it has been programmed, we are able to provide results in a mere day or two. Other services we provide such as FASTscan part-to-cad analysis, part-to-part analysis and assembly analysis are usually completed in just a couple of days. If a customer needs a part to be reverse engineered, the process can take as little as a week to be completed. In order to drive innovation forward, we dedicate ourselves to keeping up with the latest technology in 3D software and computed tomography. Our satisfaction comes from helping our customers get to production quickly and successfully. How You Benefit: Pre-programming will always make CT Scanning faster than conventional methods for complex dimensional inspections. Virtual 3D assembly analysis can save hundreds of hours. 360 analysis allows for complete capture of data points. All virtual cross sectioning keeps your parts undamaged.

19 Who is 3D ProScan? 3D ProScan is a new industrial metrology division of NyproMold* Inc. For 25 years, NyproMold has been a leader in the injection molding industry, standing among the top 10 mold making companies in the United States, making about 200 molds annually, and exporting 40% of molds globally. Founded in 1987 in Clinton, Massachusetts, NyproMold employs 160 people including over 30 engineers serving the healthcare, packaging consumer and electronics markets. In 2011, NyproMold expanded its metrology department by introducing CT scanning to its mold qualification services. CT scanning was an instant hit! Longtime customers and new customers showed great enthusiasm in the possibilities of CT scanning technology. CT scanning continues to become more popular everyday as our customers tour our facilities regularly and see for themselves the amazing features of this technology. *NyproMold is a division of Nypro, a Jabil Company

20 What Some of Our Customers Think? CT scanning services from 3DProScan have allowed us to visualize intricate structures within our assemblies, in different states of operation, enabling a full understanding of the component interactions. This information fosters better design decisions and can be applied at all stages of development. Ian Kimball, Senior Engineer, Product Development, NP Medical, Inc. We were very impressed with the capability of your process. I can foresee using this method to help us in the future. Dennis Tully, President, MTD Micro Molding Turn around is always very quick. Excellent techsupport from NyproMold/3D Proscan. Bill Siopes, R&D Manager Advanced Energy RF Disposables, Medtronic, Inc.

21 Contact Us Pleasant Street Clinton, MA USA