Pulling at the digital thread: Exploring the tolerance stack up in scan to print processes

Tobias Mahan, Brenna Doyle, Nicholas Meisel, Jessica Menold

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

The rise of affordable rapid non-contact digitizers and rapid prototyping tools, such as 3D printers, is enabling the seamless integration of geometric reverse engineering into the early phases of engineering design. Scanning technology has been widely adopted in bio-reverse engineering and the use of high fidelity non-contact scanners, such as Computed Tomography devices, allows designers, doctors, and researchers to digitally model boney structures, design orthotic and prosthetic devices, and preemptively plan complex surgeries. While the combination of 3D scanning and printing processes holds much promise for the fields of reverse engineering, biodesign, and new product development, problems with repeatability, accuracy, and precision have limited the wider spread adoption of 3D scan to print processes. While some studies have explored the errors inherent in higher fidelity scan to print (S2P) processes, no studies have explored the errors in S2P processes that leverage affordable rapid non-contact digitizers. The purpose of this study was to explore at which phases of the S2P process errors are introduced into the digital model. A controlled study was conducted using data from 27 scans using a common off-the-shelf non-contact optical digitizer and a relatively simple workpiece. Data from the digital thread was collected between each phase of the S2P process and compared against a truth model; the geometric and dimensional integrity of the data was calculated through a comparison between the digital model and the original truth model. Results indicate significant differences between digital models at the various steps of the S2P process.

Original languageEnglish (US)
Title of host publication30th International Conference on Design Theory and Methodology
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791851845
DOIs
StatePublished - Jan 1 2018
EventASME 2018 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC/CIE 2018 - Quebec City, Canada
Duration: Aug 26 2018Aug 29 2018

Publication series

NameProceedings of the ASME Design Engineering Technical Conference
Volume7

Other

OtherASME 2018 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC/CIE 2018
CountryCanada
CityQuebec City
Period8/26/188/29/18

Fingerprint

Thread
Tolerance
Reverse engineering
Non-contact
Reverse Engineering
3D printers
Orthotics
Scanning
Fidelity
Rapid prototyping
Model structures
Model
Prosthetics
Product development
New Product Development
Surgery
Tomography
Printing
Rapid Prototyping
Repeatability

All Science Journal Classification (ASJC) codes

  • Mechanical Engineering
  • Computer Graphics and Computer-Aided Design
  • Computer Science Applications
  • Modeling and Simulation

Cite this

Mahan, T., Doyle, B., Meisel, N., & Menold, J. (2018). Pulling at the digital thread: Exploring the tolerance stack up in scan to print processes. In 30th International Conference on Design Theory and Methodology (Proceedings of the ASME Design Engineering Technical Conference; Vol. 7). American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/DETC2018-85844
Mahan, Tobias ; Doyle, Brenna ; Meisel, Nicholas ; Menold, Jessica. / Pulling at the digital thread : Exploring the tolerance stack up in scan to print processes. 30th International Conference on Design Theory and Methodology. American Society of Mechanical Engineers (ASME), 2018. (Proceedings of the ASME Design Engineering Technical Conference).
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abstract = "The rise of affordable rapid non-contact digitizers and rapid prototyping tools, such as 3D printers, is enabling the seamless integration of geometric reverse engineering into the early phases of engineering design. Scanning technology has been widely adopted in bio-reverse engineering and the use of high fidelity non-contact scanners, such as Computed Tomography devices, allows designers, doctors, and researchers to digitally model boney structures, design orthotic and prosthetic devices, and preemptively plan complex surgeries. While the combination of 3D scanning and printing processes holds much promise for the fields of reverse engineering, biodesign, and new product development, problems with repeatability, accuracy, and precision have limited the wider spread adoption of 3D scan to print processes. While some studies have explored the errors inherent in higher fidelity scan to print (S2P) processes, no studies have explored the errors in S2P processes that leverage affordable rapid non-contact digitizers. The purpose of this study was to explore at which phases of the S2P process errors are introduced into the digital model. A controlled study was conducted using data from 27 scans using a common off-the-shelf non-contact optical digitizer and a relatively simple workpiece. Data from the digital thread was collected between each phase of the S2P process and compared against a truth model; the geometric and dimensional integrity of the data was calculated through a comparison between the digital model and the original truth model. Results indicate significant differences between digital models at the various steps of the S2P process.",
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Mahan, T, Doyle, B, Meisel, N & Menold, J 2018, Pulling at the digital thread: Exploring the tolerance stack up in scan to print processes. in 30th International Conference on Design Theory and Methodology. Proceedings of the ASME Design Engineering Technical Conference, vol. 7, American Society of Mechanical Engineers (ASME), ASME 2018 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC/CIE 2018, Quebec City, Canada, 8/26/18. https://doi.org/10.1115/DETC2018-85844

Pulling at the digital thread : Exploring the tolerance stack up in scan to print processes. / Mahan, Tobias; Doyle, Brenna; Meisel, Nicholas; Menold, Jessica.

30th International Conference on Design Theory and Methodology. American Society of Mechanical Engineers (ASME), 2018. (Proceedings of the ASME Design Engineering Technical Conference; Vol. 7).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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Mahan T, Doyle B, Meisel N, Menold J. Pulling at the digital thread: Exploring the tolerance stack up in scan to print processes. In 30th International Conference on Design Theory and Methodology. American Society of Mechanical Engineers (ASME). 2018. (Proceedings of the ASME Design Engineering Technical Conference). https://doi.org/10.1115/DETC2018-85844