3D scanning

Purpose: Orbital fractures are the most commonly encountered midfacial fractures, and usually, the fracture involves the floor and/or the medial wall of the orbit. This paper aims to present an innovative approach for primary and secondary reconstructions of fractured orbital walls through the use of computer-assisted techniques and additive manufacturing. Design/methodology/approach: First, through the 3D anatomical modelling, the geometry of the implant is shaped to fill the orbital defect and recover the facial symmetry. Subsequently, starting from the modelled implant, a customised mould is designed taking into account medical and technological requirements. Findings: The selective laser sintered mould is able to model and form several kind of prosthetic materials (e.g. titanium meshes and demineralised bone tissue), resulting in customised implants and allowing accurate orbital cavity reconstructions. The case study proved that this procedure, at the same time, reduces the morbidity on the patients, the duration of surgery and the related costs. Originality/value: This innovative approach has great potential, as it is an easy and in-office procedure, and it offers several advantages over other existing methods.

Keywords: Customized implant , Orbital cavity reconstruction , Reverse engineering , Selective laser sintering , Surgery , Surgical guide

To date, standard methods for assessing the severity of chest wall deformities are mostly linked to X-ray and CT scans. However, the use of radiations limits their use when there is a need to monitor the development of the pathology over time. This is particularly important when dealing with patients suffering from Pectus Carinatum, whose treatment mainly requires the use of corrective braces and a systematic supervision. In recent years, the assessment of severity of chest deformities by means of radiation-free devices became increasingly popular but not yet adopted as standard clinical practice. The present study aims to define an objective measure by defining a severity index (named External Pectus Carinatum Index) used to monitor the course of the disease during treatment. Computed on the optical acquisition of the patients' chest by means of an appositely devised, fast and easy-to-use, body scanner, the proposed index has been validated on a sample composed of a control group and a group of Pectus Carinatum patients. The index proved to be reliable and accurate in the characterization of the pathology, enabling the definition of a threshold that allows to distinguish the cases of patients with PC from those of healthy subjects. [Figure not available: see fulltext.]

Keywords: Index , Optical imaging , Pectus Carinatum , Severity assessment , Three-dimensional

This paper presents a preliminary investigation on the workflow that allows to replicate object by using 3D laser scanner and a desktop fused filament fabrication 3D printer. Pitfalls and limitations of those technologies will be pointed out in order to find the bottleneck of the workflow, paying specific attention to what concerns the digital workflow from the acquisition to the generation of the g-code. The findings and conclusions are drawn from a case study that has been carried out using the minimum amount of human intervention, especially during the digital post-processing of the data. The objects under investigation is a broken car door handle. Firstly, it has been digitalized using a 3D laser scanner properly calibrated and set. The accuracy, precision and resolution of the measurement tool have been recorded and the as-is acquired data has been checked against topological errors. The as-is acquired model has been compared with the original geometry. The 3d polygonal mesh has been prepared for being printed: the material, machine and process parameters have been chosen. A simulation of the deposition process to estimate warps and deviation from the nominal geometry was carried out. Finally, the object has been additively manufactured using a desktop Fused Filament Fabrication machine: the printed object has been again compared with the original geometry.

Background and Objective: The biomechanical analysis of the abdominal wall should take into account muscle activation and related phenomena, such as intra-abdominal pressure variation and abdomen surface deformation. The geometry of abdominal surface and its deformation during contraction have not been extensively characterized, while represent a key issue to be investigated. Methods: In this work, the antero-lateral abdominal wall surface of ten healthy volunteers in supine position is acquired via laser scanning in relaxed conditions and during abdominal muscles contraction, repeating each acquisition six times. The average relaxed and contracted abdominal surfaces are compared for each subject and displacements measured. Results: Muscular activation induces raising in the region adjacent to linea alba along the posterior-anterior direction and a simultaneous lowering along lateral-medial direction of the abdominal wall sides. Displacements reach a maximum value of 12.5 mm for the involved subjects. The coefficient of variation associated to the abdomen surface measurements in the same configuration (relaxed or contracted) is below 0.75%. Non-parametric Mann-Whitney U test highlights that the differences between relaxed and contracted abdominal wall surfaces are significant (p < 0.01). Conclusions: Laser scanning is an accurate and reliable method to evaluate surface changes on the abdominal wall during muscular contraction. The results of this experimental activity can be useful to validate numerical models aimed at describing abdominal wall biomechanics.

Keywords: Abdomen surface , Abdominal wall , Deformation , Laser scanner , Muscle contraction

During tillage, soil engaging tools are exposed to very critical working conditions due to soil friction. This produces an abrasive wear which needs to be monitored in order to avoid high costs for machine maintenance and fuel consumption and a deterioration of tillage quality. A commonly used method for wear diagnosis is the evaluation of the mass loss and volume change after a prolonged component usage. The instruments generally used for the assessment of these two quantities give only general and punctual information about the wear. Modern three-dimensional scanning technologies allow for creating a numerical model of the worn component and thereby extracting knowledge of the wear pattern. In this paper, the wear pattern of four ploughshares of a semi-mounted plough were analysed and compared. Each ploughshare was scanned by means of a structured blue-light 3D scanner before and after a prolonged field usage. From the scans, the cutting edge profile, described with three parameters, and the blade profile were calculated. The wear pattern and the volume losses were numerically calculated through Hausdorff's method and deviation analysis. Results of the experiments showed that cutting edge profile parameter of ploughshares could differ significantly from each other. Moreover, even if the wear pattern was very similar in shape for all the ploughshares, a large variability in volume losses was observed between the ploughshares. The adopted methodology permits to easily evaluate the wear pattern of tillage tools.

Keywords: 3D scanning , Abrasive wear , Blade profile , Cutting edge , Ploughshares

Topological optimization is a fairly innovative numerical technique that makes it possible to reduce the mass of mechanical components. It is an alternative to the optimizations of shape or geometry that allow to highly improve the efficiency of products. The recent development of metal additive manufacturing technologies allows the production of pieces that were not feasible before, permitting the use of topological optimization in many fields. In the biomedical field, for example, the reduction of prosthetic and orthotic materials allows to save weight, to the advantage of comfort, and to minimize the invasiveness of these systems. In this paper, an optimization of a system consisting of a femoral nail and two screws is carried out. The pieces were obtained by 3D scanning of prostheses, so as to obtain the true geometry. The femur is the standard one in literature. Following topological optimization, a new nail, with a mass of 60% of the previous one, was obtained, without limiting the functionality or the reliability of the product. Results and methodological problems are discussed.

Keywords: Additive manufacturing , Biomedical engineering , Femoral nail , Reverse engineering , Topology optimization

The use of composite materials allows to have a great flexibility in terms of mechanical and physical characteristics. One of the most used composite structure in naval field, is the sandwich, which is composed by a stacking sequence of different plies. The designer, in preliminary phase, must handle a great quantity of degree of freedom (types of materials, orientation of the fibres, position along the stack, thickness, etc.) in order to reach the best compromise between mechanical behaviour, environmental impacts and production costs. Finite Element analysis represents a useful tool in order to optimize all these parameters and to estimate the outcome of experimental tests at design stage. The main goal of this work is to develop and to validate a FE model for the simulation of a particular family of composites, widely used in naval field and, in particular, in High Speed Crafts and powerboats. The first part of the paper concerns the experimental tests on two different types of sandwich specimens. Two families of tests were conducted: four-point bending tests and impact drop tests. The second part of the paper focuses on the validation of a FE model for both experimental setups.

Keywords: Finite Element , Impact tests , Lightweight composites , Offshore powerboats , Sandwich composites

Our purpose is to develop the preoperative diagnosis stage for orthopedic surgical treatments using additive manufacturing technology. Our methods involve fast implementations of an additive manufactured bone model, converted from CAT data, through appropriate software use. Then, additive manufacturing of the formed surfaces through special 3D-printers. With the structural model redesigned and printed in three dimensions, the surgeon is able to look at the printed bone and he can handle it because the model perfectly reproduces the real one upon which he will operate. We found that additive manufacturing models can precisely characterize the anatomical structures of fractures or lesions. The studied practice helps the surgeon to provide a complete preoperative valuation and a correct surgery, with minimized duration and risks. This structural model is also an effective device for communication between doctor and patient.

Keywords: 3D-printing , Additive manufacturing-modeling , CAT scan , Diagnosis , Orthopedics , Surgery

In the era of the fourth industrial revolution the efficient sharing and exploitation of information are key success factors for companies. In order to maintain competitiveness and to answer to the requests for highly customized products, shoe last producers need to innovate their processes, by adopting digital technologies. The present paper proposes an innovative integrated approach for shoe last design and manufacturing. The process is enabled by CAD/CAM technologies, which allow to integrate the design and manufacturing phases, and by haptic technologies, which allow to interact with the virtual models to simplify the successive planning and manufacturing operations. The final aim is to support traditional companies in the implementation of the Industry 4.0 paradigm. The test case about marking operation confirms that the adoption of the proposed approach leads to a sensible improvement in the company operational efficiency, thanks to the reduction in the number of repetitive tasks.

Keywords: CAD/CAM technologies , Haptic interface , Industry 4.0 , Shoe last design

3D Printing and Additive Manufacturing technologies represent powerful tools for the direct fabrication of lightweight structures with improved and tunable properties. In current research, Fused Deposition Modeling (FDM)/3D fiber deposition technique was considered to design 3D multifunctional scaffolds with complex morphology, tailored biological, mechanical and mass transport properties. Polymeric and nanocomposite materials were used for scaffold design and optimization, with a particular focus on bone tissue engineering. As an example, poly(ϵ-caprolactone) (PCL), and PCL-based nanocomposite scaffolds were fabricated and analyzed. The effects of structural and morphological features (i.e., sequence of stacking, fiber spacing, pore size and geometry) as well as of nanoparticle inclusion on the mechanical performances were reported. Furthermore, the possibility to design 3D customized scaffolds for mandibular defect regeneration (i.e., symphysis and ramus) was also considered.

Keywords: Additive manufacturing , nanocomposites , reverse engineering , scaffold design

Surgical interventions for jaw reconstruction require the design and the production of surgical guides that allow the surgeon to operate quickly and accurately. In some cases, the reconstruction is performed by inserting a prothesis, thus operating exclusively on the jaw, while in other cases the reconstruction is performed by withdrawing and inserting part of the fibula in place of the original jaw bone. This project aims to develop a procedure that allows 3D modeling of the surgical guides necessary for surgical intervention. The idea is to find a surgical guide archetype, a starting shape for the surgeon so that the cutting planes can be oriented without the surgical guide having to be redesigned from scratch for every single patient. The first step of the procedure is the segmentation, performed applying the thresholding operation on the images provided by magnetic resonance MR in order to identify the region of interest (ROI). The second step is the reconstruction of the 3D model, so that a mesh is obtained from 2D images. Subsequently the mesh is post-processed and the cutting plans along which the surgeon will intervene are defined.

Keywords: 3D modeling , 3D reconstruction , Maxillofacial surgery , Surgical guides

In Italy's artistic heritage, there are numerous small artefacts that are rich in details usually invisible to the naked eye. In the last decade, the need to document and create digital archives of cultural heritage has triggered research on the application of well-known reverse engineering techniques. Despite the applications in the field of virtual heritage, the 3D digitalization and reconstruction of small archaeological artefacts remains an open issue due to their small dimensions and handling constraints. In this context, this paper presents a methodology to compare the performance of two different techniques for 3D digitalization, one using a triangulation laser scanner and one using Structure from Motion (SfM) photogrammetry. The methodology is based on a QFD approach to identify and quantitatively evaluate the differences between the achieved 3D models. It has been applied to the famous limestone sculpture called “Venus of Frasassi”. The main advantages and limits of both techniques are discussed with a focus on their ability to allow the identification of hidden shape features.

Keywords: Archaeology , QFD , Reverse Engineering , Virtual Heritage

Aboveground biomass (AGB) is a parameter commonly used for assessing and monitoring primary productivity of grassland communities. Destructive AGB measurements, although accurate, are time-consuming and do not allow for repeated measurements as required by monitoring protocols. Structure-from-motion (SfM) photogrammetry has been proved to be a reliable tool for rapid and not destructive AGB estimations in grass systems. Three-dimensional (3D) models of fourteen 1 × 1 m2 pasture plots were reconstructed and AGB volume measured under several measurement settings. Volume-based AGB measures were regressed to AGB values resulting from destructive methods to identify the measurement settings that show the best fit. Furthermore, 3D models of four mountain pasture plots were reconstructed in May, July, and August. Models relative to the same plot were aligned and their relative difference measured to produce a diachronic canopy variation model (DCVM). On the measured volume (Vd), the coefficient of density (cρ) was applied to adjust the volume values (Vadj) in relation to variation due to different DCVM point densities. The measurement setting for AGB volume estimations strongly influenced their correlation with traditional AGB scores. The best fit was obtained selecting 1 mm grid cell size and minimum point height distance. Such options were then selected to measure the DCVM. Adjusted volumes were fully correlated with the average point distance. Three plots revealed higher rates of AGB in the spring compared to summer season, as justified by the summer aridity constraints affecting vegetation productivity in Mediterranean areas. In one plot, we found an anomalous seasonal pattern, showing an AGB reduction in spring, which can be correlated with grazing, that promoted a subsequent increment in summer. Our study indicates that image-based photogrammetric techniques allow for reliable non-destructive measurements of surface biomass in diachronic analyses, offering a valuable tool for evaluating occurrence, magnitude, and spatial patterns of variations of community primary productivity over time. Diachronic canopy variation model produced congruent patterns of inter-seasonal canopy variations proving to be a useful tool for analyzing local disturbance to vegetation canopy caused by grazing.

Keywords: biomass , coefficient of density , diachronic variation , local disturbance , non-destructive measurements , pasture community , photogrammetry , structure-from-motion

This work deals with a novel procedure that can be used for reverse engineering (RE) of big and old boats' hull through cheap and effective instruments. The procedure has been used to acquire dimensions and shapes of an offshore boat designed by Renato Levi in 1962, named “Ultima Dea”, commissioned by Gianni Agnelli. The research purpose is the development of a method that gives to designers and restorer an “easy to use” instrument for obtaining the 2D and 3D CAD models from a degraded physical object in order to check and re-design the parts to be restored. The study and the application allowed to develop an innovative procedure to set the right acquisition parameters for optimizing the RE output in terms of minimization of maximum error and mean geometric errors between physical object and virtual model, by using a one-shot RE operation and a completely off-line post-processing. This procedure ensures good timesaving, during acquisition, very high reliability level and lightness of CAD models, also being able to reconstruct worn down and spoiled parts (through ex-novo modelling). The procedure shows how the CAD-modelling step can be done directly on graphical models (without surfaces' mathematics) while ensuring the appropriate level of detail and, contemporarily, improving the interoperability of used and developed software. This procedure is based on the use of well-known methodologies and instruments that usually are employed in architectural relief; finally, it allowed to model the boat's hull for the redesigning of engine/electrical/services systems and to restore the boat completely.

Keywords: Polygon mesh modelling , Reverse engineering , Yacht design

High-flexibility components in composite material are of great interest in many fields, from aeronautic and automotive industries to sport and design goods. Their deformation during cure process, known as spring-in and warpage, is acceptable if it is within the indicated tolerance. The research aim of the present work is to present a way to inspect a high flexible part in composite material by means of a coordinate measuring machine with a touch probe. This means to define the fixturing equipment and the measurement strategy. The developed method was applied to an L-shaped part with a very small thickness and the obtained measurements were compared with those due to a laser system. The results show a good agreement between the two measurement techniques. Moreover, the further numerical simulations validate the developed contact measurement method.

Keywords: Composite material , Coordinate measuring machine , Flexible component , Laser

The preservation status of an underwater cultural site can be determined as the combination of two primary factors, namely the site physical integrity, which results from the past and present interaction of the site itself with the biological/chemical agents located in the surrounding environment, and the exposure of the site to human-related threats. Methods to survey underwater archaeological sites have evolved considerably in the last years in order to face the challenges and problems in archaeological prospection, documentation, monitoring, and data collection.This paper presents a case-study of an archaeological documentation campaign addressed to study and monitor the preservation status of an underwater archaeological site by combining the quantitative measurements coming from optical and acoustic surveys with the study of biological colonization and bioerosion phenomena affecting ancient artefacts. In particular, we present the first results obtained in the survey and documentation campaign carried out during the spring - summer 2018 in the "Nymphaeum of Punta Epitaffio" located in the Marine Protected Area - Underwater Park of Baiae (Naples).

Keywords: 3D Imaging , 3D Mapping , Baiae Archaeological Park , Photogrammetry , Underwater Archaeology

Objectives: To evaluate the association between maxillary dental arch transverse dimensions, palatal depths, palatal area and volume with buccally displaced canine (BDC) in mixed dentition subjects when compared to non-BDC subjects using laser scanner 3D technology. Materials and methods: Sixty Caucasian subjects, 8-11 years of age (mean, 9.26 ± 1.48 years), were included. In each group (BDC and non-BDC) 30 children were matched. Digital dental casts were obtained using a 3 Shape D700 laser scanner. Intercanine and intermolar widths (cusp and gingival levels), anterior and posterior palatal depth (cusp level), palatal surface area and volume were measured. An independent sample Student's t-test and an ANOVA were undertaken with significance level set as P < 0.05. Results: Intercanine widths at the cusp (1.76 mm; P = 0.020) and the gingival level (1.6 mm; P = 0.006), palatal area (133 mm2; P = 0.021) and volume (790 mm3; P = 0.046) were significantly lower in the BDC compared to the control group. Limitations: A smaller part of the subjects was in late mixed dentition phase. To overcome this limitation a matched control group was used. Some subjects did not have some teeth because of the transition phase which might have had an influence on the dental measurements. However, these subjects were not excluded to avoid introducing a bias. Conclusions: 3D evaluation of the maxillary arch and palate highlighted significant differences between BDC and non-BDC mixed dentition subjects. Maxillary dental arch dimensions and palate morphology may allow early identification and prevention of maxillary canine impaction.

Computational Fluid Dynamics (CFD), as early used in the design stage, helps engineers to come up with the optimum design of a sail in a reasonable timeframe. However, traditional CFD tools are approximate and need to be validated when it comes to predicting the dynamic behaviour of non-developable shape with high camber and massively detached flow around thin and flexible membranes. Some of these approximations are related to the implementation of the constitutive material characteristics and assumption of their isotropic properties, while the sail aerodynamic performance is strongly influenced by the arrangement of sail panels as well as the orientation of the fibres in the composite structure. The present paper offers a methodology that enhances the understanding of the influence of panel arrangement and fibre orientation on sail performance. Fluid-structure-interaction (FSI) in a symmetric spinnaker was studied through an integrated CFD-CSM (Computational Structural Mechanics) analysis. A suitable triangular membrane element formulation of sail was adopted and the constitutive characteristics (elasticity and damping) of the Nylon superkote 75 were implemented in CSM model after being experimentally measured. The aerodynamic performance of sail in terms of drive force and side force was evaluated using both Reynolds Averaged Navier Stokes Simulations (RANS) and Shear Stress Transport (SST) turbulence model with a finite volume approach. A comparison between different panel arrangements was carried out under altered downwind flow conditions of wind speed and wind angle. Digital photogrammetry was employed to create the 3D reconstruction of the sail's flying shape and validate the results obtained by aeroelastic analysis.

Keywords: CFD-CSM analysis , Flying shape photogrammetry acquisition , Sail panel arrangement , SST model , Triangular membrane elements

In this work is exploited the possibility to use two optical techniques and combining their measurements for the 3D characterization of different tyres with particular attention to the tyre's section. Electronic Speckle Pattern Interferometry (ESPI) and Laser Scanner (LS) based on principle of triangulation have been employed for investigating and studying the tyre's section and 3D shape respectively. As case studies two different racing tyres, Michelin S9H and Pirelli Diablo respectively, have been considered. The investigation has been focused at the aim to evaluate and measure the section's components in order to add to the 3D model obtained by Laser Scanning accurate information about the different layers along through the tyres sections. It is important to note that the assessment about the different layers along the section is a very difficult task to obtain by visual inspection or classical microscopy and even with the LS. Here we demonstrate that the different layers can be easily highlighted and identified by mean of the ESPI.

Keywords: Holography , Laser scanner , Non-destructive testing , Speckle , Tyre characterization , Tyre layer thickness measurement