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3D Scanning for 3D Printing: 
Making Reality Digital, and then Physical Again, Part 2 
Michael Raphael 
Founder and CEO 
Direct Dimensions, Inc. 
© Copyright 2014 FARO The information contained herein is subject to change without notice.
Biography – Michael Raphael 
Education 
• B.S. in Engineering Science & Mechanics (VT) 
• Masters in Engineering Administration (GWU) 
Career 
• Liaison Engineer at Martin Marietta (Lockheed Martin) 
• Roles in engineering and quality departments 
• Created Advanced Quality Technologies group to resolve 
engineering and manufacturing problems 
• Co-developed the electrogoniometer (FaroArm!) in 1989 
Direct Dimensions 
• Founded DDI in 1995 as ’one-stop 3D scanning shop’ 
Professional Life 
• Author for LiDAR News – numerous articles on scanning 
• Contributor to Wohler’s Report – the 3D Scanning section 
• Active with many 3D conferences: SPAR, CMSC, RAPID, etc.
Overview of Direct Dimensions, Inc. 
Offers a wide range of services & tools for the 3D scanning and printing worlds 
Rapid Solutions to 3D Problems: 
• 20-year experts in coordinate metrology for reverse engineering & inspection 
• 1000’s of 3D laser scanning and point cloud processing projects 
• 3D CAD & BIM modeling, and visualization/animation 
• Processing of 3D data for reproductions and 3D printing 
• Product sales and application support and training 
• Specialized 3D applications and process development 
• Creators of ShapeShot 3D Photo Booth
Overview of Direct Dimensions, Inc. 
Offers a wide range of services & tools for the 3D scanning and printing worlds 
History and experience: 
• Participated in the development of the Faro Arm PCMM 
• Founded Direct Dimensions in 1995 to provide 3D solutions to the aerospace industry 
• Maintains a comprehensive arsenal of 3D scanners, measurement tools, and software 
• Completed thousands of project across various industries and applications served 
• Today, 25+ employees with vast professional expertise and real-world 3D experience
Overview of Direct Dimensions, Inc. 
Offers a wide range of services & tools for the 3D scanning and printing worlds 
Key industries served: 
• Most Industrial Applications 
• Military & Defense 
• Buildings & Facilities (AEC/BIM) 
• Art, Sculpture, Museum 
• Historic Preservation 
• Entertainment and TV/Movie VFX 
• Digital Fabrication & 3D Printing 
• Model Preparation for 3D Printing
3D PRINTING & SCANNING Gartner's Hype Cycle
3D PRINTING & SCANNING Gartner's Hype Cycle
3D Scanning vs. 3D Printing 
Both over 20 years old, actually 30 years old 
• largely industrial with recent consumer interest 
• Was $100K+ equipment cost with now sub-$1K 
Range of objects 
• physical world has huge size & complexity variation 
Massive change over last 3 years 
• “desktop” and personal 3D scanning 
• 123D Catch and Xbox Kinect 
Future – what’s next? 
• who needs 3D scanning and why? 
• what will be the ‘killer apps’?
Traditional 3D Printing & Additive Manufacturing 
• Visual aids for engineers, 
designers, sales, medical, etc. 
• Presentation models, such as 
architectural or prototypes 
• Prototypes for assembly fit checks 
• Patterns for tooling and castings 
• Guides for surgery procedures 
• Functional short run production 
• Education and research 
• Other
Main 3D Printing Processes and Materials 
PROCESS SYSTEMS MATERIALS 
Material Extrusion - FDM 
Stratasys Dimensions, uPrint 
MakerBot Replicator 
ABS 
PLA 
Material Jetting – jetting 
drops of material (like inkjet) 
Vat photo-polymerization 
(light cured) 
Objet Connex 
Stratasys Polyjet 
Multiple plastics or resins 
various color and 
transparancies 
Binder Jetting – glue binds 
layered materials 
Z Printer 
Projet x60 Series 
Projet 4500 
Composite powders 
Plastics 
Full color 
Sheet Lamination MCOR 
Colors, cuts and glues sheets 
of paper 
Selective Laser Sintering 
(SLS) 
EOS 
3D Systems ProX and sPro 
Selectively fusing powder 
materials – Nylon, 
polystyrene, metals
What else is being 3D printed?
Projecting the future for 3D printing 
Market Research and Analysis - Source: Pete Basiliere, Research Director at Gartner 
3D printing remains a emerging market, despite high levels of hype: 
 Growing demand for easy-to-use tools and materials 
 Prices to drop with competitive pressures and higher unit sales 
 Advances in 3D printers  scanners, design tools, and 
materials will reduce the cost and complexity of creating 3D 
printed item 
 Businesses are only now beginning to fully comprehend ways 
in which a 3DP can be cost-effectively used in their 
organizations 
 Makers and hobbyists will contribute to some form of “plug 
and play” tool — that will be key to driving consumer sales in 
future
Considerations 
 Define your niche: What customers 
will you best serve? 
 What role: Will you print as a service, 
sell the equipment or both? 
 Which Equipment  Materials? 
 Content: Where will it come from? 
Who will own it? 
 Data repair: How will you address 
the need for scan data processing 
into 3D printable files? 
“…making stuff is going to become more 
localizable. ..more objects can be 
manufactured closer to the end customers.” 
(Peter Weijmarshausen, CEO Shapeways – 
BARRONS.COM 5/9/14) 
Microsoft 8.1 has added a direct pipeline from 
3D printing applications to 3D printers-(PC 
Magazine – 7/2/13) 
About HP - The company believes that 3D 
printing is a natural progression of its 2D printer 
business, where it has a sizeable share. 
(FORBES.COM – 3/28/14)
3D Scanning – Building content
NYC Hotel Courtyard: Scan to Model to Print
NYC Hotel Courtyard: Scan to Print 
 Four Focus3D 120 scans taken at NYC hotel 
 Total time on-site about 40 minutes 
 Data sufficient for preliminary architectural 
modeling of courtyard and portions of 
surrounding buildings 
 Point cloud converted into 3D CAD model 
 3D CAD fabricated by 3D printing
3D Scan to Revit (BIM) to 3D print example
Feature Replication
Feature Replication
Building Documentation
3D Scanning 
The DDI technicians scanned four different sculptures: the Amun, the Headless Princess, the Scribe, and a 
Kneeling King Tut. An articulating arm-based laser line scanner provided high accuracy and real-time feedback 
to assure complete capture before heading back to Baltimore to process the raw scan data. 
Ancient Sculptures
3D Modeling 
For the post-processing, we used Innovmetric’s PolyWorks Modeler software to create highly accurate 
watertight 3D digital models of each of the ancient pieces. 
Ancient Sculptures
Data Analysis 
During both the scanning and modeling processes, specific attention was paid to fine cracks and other 
imperfections in the original pieces. These are the qualities that would make the reproductions more 
accurate and realistic. 
Ancient Sculptures
Final Product Ancient Sculptures
Half-Scale RCPa Mseo Sdtuedly I Digital Historic Preservation I Tomb of the Unknowns
Creating the CFaisnea Sl tMudoyd IeDligital Historic Preservation I Tomb of the Unknowns
Team “Scantasia” 
3D Scanning Museum Sculptures for 
Conservation, Restoration, and Awesome 
Interactive 3D Online Display
http://shpws.me/qB6j
http://shpws.me/qBrD
http://sketchfab.com/dirdim
https://sketchfab.com/nm5l43hgca
Team Scantasia 
Deliverables to The Walters Art Museum 
• Demonstration of various types of 3D scanning 
• Accurate 3D documentation for conservators  curators 
• Various outlets for 3D model presentation to public: 
• Shapeways for 3D printing 
• Sketchfab for interactive online 3D viewing 
• WordPress integration to existing website content 
http://dirdim.sketchfab.me/folders/artbytes-2014-from-walters-art-museum
1 
6 ft. Youthful Franklin 
3D Scanned Onsite 
2 
3D Computer Model 
from 3D Scanning 
Digital 
Fabrication 
from 3D 
Model 
Laser Etched Crystal 
3 
8 and 12 inch 
3D Printed Patterns: 
8 Inch Bronze 
Replica 4
Life-Sized Sculpture 
of Teddy Roosevelt 
3D Scanned in Museum 
High Resolution 
3D Digital Model 
1 
3 
2 
Casting Pattern made with 3D Printing 
4 
6” Stone Replica 
with Faux Bronze Finish
2 
3D Digital Model of 
Rosetta Stone 
Hieroglyphs 
Extreme High Resolution 3D 
scanning of the direct cast 
replica of the Rosetta Stone 
1 
3 
High Resolution 
Casting Pattern made 
with 3D Printing 
4 
12 and 15 inch Cast Stone 
Rosetta Stone Replicas
High Resolution Scanning of a 
Moth and the Resulting 
Cast Silver Pendant
2
Click image for link to main Vogue story 
Behind the scenes story #2 Story #3 Story #4
Liars Music Video
1. ShapeShot 3D Photo Booth automatically 
captures face in 3D in high-res and accurately 
3D Photo Booth 
4. Files sent to our service providers for fulfillment 
2. Instantly view your personal on-line 
gallery and on ShapeShot mobile app 
3. Buy personalized products from our 
ShapeShot online Marketplace web store
Thank You

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3D Scanning for 3D Printing: Making Reality Digital and then Physical Again, Part 2 By Michael Raphael

  • 1. 3D Scanning for 3D Printing: Making Reality Digital, and then Physical Again, Part 2 Michael Raphael Founder and CEO Direct Dimensions, Inc. © Copyright 2014 FARO The information contained herein is subject to change without notice.
  • 2. Biography – Michael Raphael Education • B.S. in Engineering Science & Mechanics (VT) • Masters in Engineering Administration (GWU) Career • Liaison Engineer at Martin Marietta (Lockheed Martin) • Roles in engineering and quality departments • Created Advanced Quality Technologies group to resolve engineering and manufacturing problems • Co-developed the electrogoniometer (FaroArm!) in 1989 Direct Dimensions • Founded DDI in 1995 as ’one-stop 3D scanning shop’ Professional Life • Author for LiDAR News – numerous articles on scanning • Contributor to Wohler’s Report – the 3D Scanning section • Active with many 3D conferences: SPAR, CMSC, RAPID, etc.
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  • 5. Overview of Direct Dimensions, Inc. Offers a wide range of services & tools for the 3D scanning and printing worlds Rapid Solutions to 3D Problems: • 20-year experts in coordinate metrology for reverse engineering & inspection • 1000’s of 3D laser scanning and point cloud processing projects • 3D CAD & BIM modeling, and visualization/animation • Processing of 3D data for reproductions and 3D printing • Product sales and application support and training • Specialized 3D applications and process development • Creators of ShapeShot 3D Photo Booth
  • 6. Overview of Direct Dimensions, Inc. Offers a wide range of services & tools for the 3D scanning and printing worlds History and experience: • Participated in the development of the Faro Arm PCMM • Founded Direct Dimensions in 1995 to provide 3D solutions to the aerospace industry • Maintains a comprehensive arsenal of 3D scanners, measurement tools, and software • Completed thousands of project across various industries and applications served • Today, 25+ employees with vast professional expertise and real-world 3D experience
  • 7. Overview of Direct Dimensions, Inc. Offers a wide range of services & tools for the 3D scanning and printing worlds Key industries served: • Most Industrial Applications • Military & Defense • Buildings & Facilities (AEC/BIM) • Art, Sculpture, Museum • Historic Preservation • Entertainment and TV/Movie VFX • Digital Fabrication & 3D Printing • Model Preparation for 3D Printing
  • 8. 3D PRINTING & SCANNING Gartner's Hype Cycle
  • 9. 3D PRINTING & SCANNING Gartner's Hype Cycle
  • 10. 3D Scanning vs. 3D Printing Both over 20 years old, actually 30 years old • largely industrial with recent consumer interest • Was $100K+ equipment cost with now sub-$1K Range of objects • physical world has huge size & complexity variation Massive change over last 3 years • “desktop” and personal 3D scanning • 123D Catch and Xbox Kinect Future – what’s next? • who needs 3D scanning and why? • what will be the ‘killer apps’?
  • 11. Traditional 3D Printing & Additive Manufacturing • Visual aids for engineers, designers, sales, medical, etc. • Presentation models, such as architectural or prototypes • Prototypes for assembly fit checks • Patterns for tooling and castings • Guides for surgery procedures • Functional short run production • Education and research • Other
  • 12. Main 3D Printing Processes and Materials PROCESS SYSTEMS MATERIALS Material Extrusion - FDM Stratasys Dimensions, uPrint MakerBot Replicator ABS PLA Material Jetting – jetting drops of material (like inkjet) Vat photo-polymerization (light cured) Objet Connex Stratasys Polyjet Multiple plastics or resins various color and transparancies Binder Jetting – glue binds layered materials Z Printer Projet x60 Series Projet 4500 Composite powders Plastics Full color Sheet Lamination MCOR Colors, cuts and glues sheets of paper Selective Laser Sintering (SLS) EOS 3D Systems ProX and sPro Selectively fusing powder materials – Nylon, polystyrene, metals
  • 13. What else is being 3D printed?
  • 14. Projecting the future for 3D printing Market Research and Analysis - Source: Pete Basiliere, Research Director at Gartner 3D printing remains a emerging market, despite high levels of hype: Growing demand for easy-to-use tools and materials Prices to drop with competitive pressures and higher unit sales Advances in 3D printers scanners, design tools, and materials will reduce the cost and complexity of creating 3D printed item Businesses are only now beginning to fully comprehend ways in which a 3DP can be cost-effectively used in their organizations Makers and hobbyists will contribute to some form of “plug and play” tool — that will be key to driving consumer sales in future
  • 15. Considerations Define your niche: What customers will you best serve? What role: Will you print as a service, sell the equipment or both? Which Equipment Materials? Content: Where will it come from? Who will own it? Data repair: How will you address the need for scan data processing into 3D printable files? “…making stuff is going to become more localizable. ..more objects can be manufactured closer to the end customers.” (Peter Weijmarshausen, CEO Shapeways – BARRONS.COM 5/9/14) Microsoft 8.1 has added a direct pipeline from 3D printing applications to 3D printers-(PC Magazine – 7/2/13) About HP - The company believes that 3D printing is a natural progression of its 2D printer business, where it has a sizeable share. (FORBES.COM – 3/28/14)
  • 16. 3D Scanning – Building content
  • 17. NYC Hotel Courtyard: Scan to Model to Print
  • 18. NYC Hotel Courtyard: Scan to Print Four Focus3D 120 scans taken at NYC hotel Total time on-site about 40 minutes Data sufficient for preliminary architectural modeling of courtyard and portions of surrounding buildings Point cloud converted into 3D CAD model 3D CAD fabricated by 3D printing
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  • 22. 3D Scan to Revit (BIM) to 3D print example
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  • 47. 3D Scanning The DDI technicians scanned four different sculptures: the Amun, the Headless Princess, the Scribe, and a Kneeling King Tut. An articulating arm-based laser line scanner provided high accuracy and real-time feedback to assure complete capture before heading back to Baltimore to process the raw scan data. Ancient Sculptures
  • 48. 3D Modeling For the post-processing, we used Innovmetric’s PolyWorks Modeler software to create highly accurate watertight 3D digital models of each of the ancient pieces. Ancient Sculptures
  • 49. Data Analysis During both the scanning and modeling processes, specific attention was paid to fine cracks and other imperfections in the original pieces. These are the qualities that would make the reproductions more accurate and realistic. Ancient Sculptures
  • 50. Final Product Ancient Sculptures
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  • 56. Half-Scale RCPa Mseo Sdtuedly I Digital Historic Preservation I Tomb of the Unknowns
  • 57. Creating the CFaisnea Sl tMudoyd IeDligital Historic Preservation I Tomb of the Unknowns
  • 58. Team “Scantasia” 3D Scanning Museum Sculptures for Conservation, Restoration, and Awesome Interactive 3D Online Display
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  • 79. Team Scantasia Deliverables to The Walters Art Museum • Demonstration of various types of 3D scanning • Accurate 3D documentation for conservators curators • Various outlets for 3D model presentation to public: • Shapeways for 3D printing • Sketchfab for interactive online 3D viewing • WordPress integration to existing website content http://dirdim.sketchfab.me/folders/artbytes-2014-from-walters-art-museum
  • 80. 1 6 ft. Youthful Franklin 3D Scanned Onsite 2 3D Computer Model from 3D Scanning Digital Fabrication from 3D Model Laser Etched Crystal 3 8 and 12 inch 3D Printed Patterns: 8 Inch Bronze Replica 4
  • 81. Life-Sized Sculpture of Teddy Roosevelt 3D Scanned in Museum High Resolution 3D Digital Model 1 3 2 Casting Pattern made with 3D Printing 4 6” Stone Replica with Faux Bronze Finish
  • 82. 2 3D Digital Model of Rosetta Stone Hieroglyphs Extreme High Resolution 3D scanning of the direct cast replica of the Rosetta Stone 1 3 High Resolution Casting Pattern made with 3D Printing 4 12 and 15 inch Cast Stone Rosetta Stone Replicas
  • 83. High Resolution Scanning of a Moth and the Resulting Cast Silver Pendant
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  • 95. Click image for link to main Vogue story Behind the scenes story #2 Story #3 Story #4
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  • 99. 1. ShapeShot 3D Photo Booth automatically captures face in 3D in high-res and accurately 3D Photo Booth 4. Files sent to our service providers for fulfillment 2. Instantly view your personal on-line gallery and on ShapeShot mobile app 3. Buy personalized products from our ShapeShot online Marketplace web store
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