DDI Dense Point Cloud Processing Presentation Oct 2009

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With the advent of higher powered 3D scanners comes the challenge of dealing with the dense point cloud data sets. Direct Dimensions uses a wide variety of 3D scanning equipment to capture the …

With the advent of higher powered 3D scanners comes the challenge of dealing with the dense point cloud data sets. Direct Dimensions uses a wide variety of 3D scanning equipment to capture the as-built shape of existing objects. The common problem with all of these projects is the need to proces the point cloud data.

While applications fall generally into either reverse engineering and inspection, both directions present challenges for processing the large data sets efficiently, quickly, and properly. This presentation will focus on an overview of the software tools available commercially that address these problems with a comparison of the various workflows, strategies, and results that one can expect from the various solutions.

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  • 1. Dense 3D Scan Point Cloud Processing Software Review Peter Kennedy Michael Raphael www.directdimensions.com [email_address] [email_address] 410-998-0880
  • 2.
    • About Direct Dimensions, Inc.
    • Technical Expertise Areas
    • Products and Capabilities
    • Typical Workflow
    • Points to Polygons
    • Case Studies
      • C5A Interference Study
      • Texas A&M NASA Gulfstream 2
      • Graving Dock
    • Interactive Discussion
    Table of Contents Dense 3D Scan Point Cloud Processing Software Review
  • 3. rapid solutions to 3D problems... Direct Dimensions, Inc.
    • Leading Experts in Close-Range 3D Imaging
    • Widest Toolset for Portable 3D Metrology
    • Specialists in Manufacturing Problems
    • Reverse Engineering to CAD Models
      • Raw Data into Surfaces & Solids
      • Engineering for “Design Intent”
    • Complex 3D Inspection and FAI’s
    • Thousands of Successful Projects
    • 14-years of Experience, Staff over 20
    • One-Stop-Shop for Expert 3D Scanning
  • 4. Technical Expertise Areas Military/Aerospace Automotive Industrial Consumer Products Medical Art/Architecture 1000s of Projects for 100s of Customers Direct Dimensions, Inc.
  • 5.
    • Hardware
    • FARO Portable CMMs & Scanners
    • FARO Large-Volume Scanners
    • LDI SLP Laser Scanner
    • Basis Software Surphaser
    • Steinbichler Comet 5 White-Light
    • Kreon Zephyr Laser Scanner
    • Konica Minolta VIVID and Range7
    • ViALUX z-Snapper 3D Camera
    • Software
    • PolyWorks
    • Geomagic
    • Rapidform
    • Imageware
    • 3D-Doctor
    • Pointools
    • FARO CAM2
    • Rhino3D
    • RevWorks
    • Verisurf
    Products and Capabilities Direct Dimensions, Inc.
  • 6. Example Data Alignment and Processing Software Typical Dense Point Cloud Processing Workflow Example Data Collection Equipment Aligned Point Clouds and Polygonal Models
  • 7. Aligned Point Cloud Polygonal Model Final CAD Typical Dense Point Cloud Processing Workflow Modeling Software
  • 8.
    • User has large amount of control
    • Distributed processing
    • Still a significant time investment with a high density point cloud
    Points to Polygons Dense Point Cloud Polygon Model Creation Do not take advantage of distributed processing at this time
  • 9. C5A Interference Study Project Overview
    • Customer Interested in virtual test fit of a large cargo pallet
    • Massive interior cabin also contains many small components required by customer
    • Interior cabin measurements:
      • 121 feet long
      • 13.5 feet high
      • 19 feet wide
    • Large Scale Object including Small details required high resolution scans
  • 10. C5A Interference Study Detail Overview
  • 11. C5A Interference Study Measurement Tools Surphaser HSX IR 3D Spherical Laser Scanner Faro Laser Tracker
  • 12. C5A Interference Study Scanning Approach
  • 13. C5A Interference Study Sphere Location Close-Up
  • 14.
    • Approximately 2 billion points collected
    • Very large file sizes- File I/O slow
    • Must retain full resolution on small details throughout the aircraft
    • Project timeline- 4 weeks total from scanning to delivery of engineered surface model
    C5A Interference Study Processing Challenges
  • 15. C5A Interference Study Processing Solutions High-End Workstations accelerate processing and alignment - Dual quad core cpu’s - Nvidia Quadro FX4600 GPU -16GB+ RAM -15,000 RPM SAS hard drives
    • 64-bit PolyWorks V10 utilized for alignment of Surphaser scans
      • N-pairs of center points alignment in IMinspect module used
    • Multiple Users align scans to Laser Tracker coordinate system concurrently
    • Section out specific areas of interest for full resolution and decimate remainder
    • Break up large point clouds into manageable sections for downstream CAD work
  • 16.  
  • 17.
    • Customer designing new wing and needed a model of current configuration
    • Scanned using Surphaser HSX IR
    • No tracker used for coordination
    • Small details required very high resolution scans (ex. vortex generators)
    • PolyWorks used for alignment and point cloud export
    • Imageware used for modeling
    • SolidWorks utilized for stitching surface models into solids
    NASA Gulfstream II Project Overview Vortex generators on top of wing
  • 18. NASA Gulfstream II Project Challenges
    • Capturing entire airplane at resolution required for smallest detail
    • 38 Surphaser scans containing roughly 2 billion points (not all scans full 360 degrees)
    • Ensuring scan encompassed all areas of interest
    • Scan alignment without master coordinate system from laser tracker
    • Chrome surface finish on leading edges of wings and engine nacelles
  • 19. NASA Gulfstream II Project Solutions
    • Utilized high-end workstations running 64-bit PolyWorks V10.1.17 to import PTX files for
      • alignment and export of clean point clouds
    • Paid special attention to ensure comprehensive scan coverage
      • Adequate coverage of spheres critical to alignment quality
      • Took obvious occlusions such as engine pylons and wings into account
    • Iteratively aligned scans using 6” spheres placed on and around the aircraft
      • Proved to be more difficult than the laser tracker approach
    • Blue painters tape was applied to shiny areas on the aircraft
  • 20.  
  • 21.  
  • 22.
    • Existing condition of 1960’s-era dry dock
    • Structural failure occurred
    • 800’ long, 75’ high, 100-ft across
    Graving Dock Electric Boat Corp.
  • 23.
    • Raw data assembled virtually and organized into geographical segments
    Graving Dock Electric Boat Corp.
  • 24.
    • Portions of the finished polygon shell
    • High level detail allows for accurate analysis
    Graving Dock Electric Boat Corp.
    • Polygons were then NURBS surfaced
  • 25.
    • Final model as a solid in Pro-E
    • 3 different models assembled: Coffer Dams (gray), Rock Wall (red), Concrete Columns (blue)
    Graving Dock Electric Boat Corp.
  • 26. Dense 3D Scan Point Cloud Processing Software Review Thank You! Questions? Michael Raphael and Peter Kennedy www.directdimensions.com [email_address] [email_address] 410-998-0880