Dense 3D Scan Point Cloud Processing Software Review Peter Kennedy Michael Raphael www.directdimensions.com [email_address] [email_address] 410-998-0880

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

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

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

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

Technical Expertise Areas Military/Aerospace Automotive Industrial Consumer Products Medical Art/Architecture 1000s of Projects for 100s of Customers Direct Dimensions, Inc.

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.

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

Example Data Alignment and Processing Software Typical Dense Point Cloud Processing Workflow Example Data Collection Equipment Aligned Point Clouds and Polygonal Models

Aligned Point Cloud Polygonal Model Final CAD Typical Dense Point Cloud Processing Workflow Modeling Software

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

User has large amount of control

Distributed processing

Still a significant time investment with a high density point cloud

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

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

C5A Interference Study Detail Overview

C5A Interference Study Measurement Tools Surphaser HSX IR 3D Spherical Laser Scanner Faro Laser Tracker

C5A Interference Study Scanning Approach

C5A Interference Study Sphere Location Close-Up

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

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 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

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

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

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 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

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

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

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

Existing condition of 1960’s-era dry dock Structural failure occurred 800’ long, 75’ high, 100-ft across Graving Dock Electric Boat Corp.

Existing condition of 1960’s-era dry dock

Structural failure occurred

800’ long, 75’ high, 100-ft across

Raw data assembled virtually and organized into geographical segments Graving Dock Electric Boat Corp.

Raw data assembled virtually and organized into geographical segments

Portions of the finished polygon shell High level detail allows for accurate analysis Graving Dock Electric Boat Corp. Polygons were then NURBS surfaced

Portions of the finished polygon shell

High level detail allows for accurate analysis

Polygons were then NURBS surfaced

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.

Final model as a solid in Pro-E

3 different models assembled: Coffer Dams (gray), Rock Wall (red), Concrete Columns (blue)

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