3D scanning

The use of intraoral scanners and Additive Manufacturing (AM) techniques in dentistry is increasing, and such technologies are integrated in daily workflows for the production of various types of dental restorations. Thus, it is clinically sensible to assess the accuracy of these systems. This in vivo study presents a comparison, in term of accuracy, among three commercially available AM systems, used to rapid prototype models obtained from intraoral scans data. Eight patients with a complete dentition were selected. Complete-arch scans of both upper and lower jaws were obtained using the 3Shape Trios 3 color intraoral scanner. The corresponding CAD models were created by means of the 3Shape Dental System software, and three AM systems, Photocentric LC10 (AM1), Zortrax M 200 (AM2) and Prusa I3 (AM3) were used to manufacture them. The manufactured fourty-eight models were scanned with the 3Shape Trios 3 color scanner, by the same operator. Scans of the manufactured models were aligned and compared to the reference intraoral scan by means of a Reverse Engineering software (Geomagic Studio). The comparison between the scans of the manufactured models and the reference intraoral scans, for the eight patients, shows a standard deviation (SD) in the range 0.11 – 0.27 mm for AM1, in the range 0.04 – 0.26 mm for AM2 and in the range 0.07 – 0.26 mm for AM3. The results of this research show that Prusa I3 and Zortrax M 200 are statistically more accurate than Photocentric LC10. Nevertheless, if we consider the amount of difference in accuracy, this may be not relevant from a clinical point of view. Thus, the three AM systems can be used in some dental applications which are compatible with the reported accuracy.

Keywords: Additive manufacturing , Dental models , Dentistry , Intraoral scans , Orthodontic appliances

In the past few years, a new generation of additive manufacturing (AM) techniques has rapidly become available due to the expiration of some AM patents which allowed significant cost reductions. This article explores some available techniques fostering products innovation in experimental laboratories for the development of naval propulsion, where high costs represent an important limitation for both basic research and industrial testing, by identifying significant knowledge and variables and by providing reliable and accurate data to support designers and researchers. The propeller INSEAN E779a case study was taken into account and fabricated by direct metal laser sintering in AlSi10Mg aluminium alloy and by fused deposition modeling in acrylonitrile–butadiene–styrene, and UltraT polymeric materials. The study of printing parameters, flexural tests, differential scanning calorimetry and thermogravimetric analysis, allowed to optimize the printing process conditions. A reverse engineering system, Faro-CAM2, and the iterative closest point algorithm of the geomagic control software were used to analyse deviations from the printed propeller and the CAD nominal model. The atomic force microscopy test allowed to assess the morphological features and surface roughness of printed propellers. Towing Tank tests were carried out and the hydrodynamic performance comparison was analysed in terms of torque and drag. The results of this study show differences between the benchmark and AM propellers, as a function of the advance coefficient J, the morphological characteristics and the materials. However this study also shows a substantial adequacy of AM propellers in most studies carried out in Towing Tank.

Keywords: Additive manufacturing (AM) , Marine propeller , Reverse engineering (RE)

The objective of the work is to describe the design and the realization of a virtual simulator of a metropolitan railway cockpit, aimed at improving the perception of safety by means of tests made by users in Virtual Reality, analysed through statistical methodologies. The user lives the experience of a driver in an immersive and interactive Augmented Reality session, interacting with the train dashboard and all its control and signalling devices. In particular, the user is proposed to test different dashboards, different configurations of the controls and different signalling and safety devices in order to compare different concept and select the optimum in terms of perception of dangerous situation, reaction to an event and cognitive response in different situations of the rail vehicle driving. The simulator consists of a simulacrum integrating different technologies, physically composed of a dashboard of the cockpit of a metropolitan train and a real seat. The geometry of the dashboard has been acquired through Reverse Engineering techniques from a real train dashboard. The user's immersion in the virtual environment during the simulation is guaranteed by the scene displayed on the Augmented Reality device, while, simultaneously, the stereoscopic projection on a screen above the dashboard makes available the experience even to users not directly involved, seeing the scene from the driver's point of view. The immersive Augmented Reality is realized through a Head-Mounted Display (HMD) by which the user, protagonist of the driving experience, sees the configuration of the virtual control devices (CAD geometries) overlapped with the physical dashboard in order to naturally interact into the immersive environment. The interaction between user and simulator happens through the NUI (Natural User Interfaces) based on markerless tracking of parts of the user's body.

Keywords: Augmented reality , Head-mounted display , IDEAinVR , Natural user interfaces , Preventive safety , Railway design , Reverse engineering , Train dashboard , Vehicle driving , Vitual simulator

Despite the widespread use of reverse total shoulder arthroplasty, the fundamental effects of implant configuration on certain biomechanical outcomes have not been completely elucidated especially for the most innovative prostheses. Aim of this work is to investigate the behaviour of a new reverse shoulder prosthesis, characterized by a humeral tray with a variable offset, designed to increase the range of motion and to reduce the impingement. The purposes of this study were to evaluate the effect of reverse shoulder implant design parameters on the deltoid muscle forces, required to produce abduction, and on the shoulder range of motion, in order to provide a more systematic understanding of the fundamental effects of humeral component positioning on the implant performances. The study has been implemented using virtual prototypes of the shoulder-prosthesis assembly. The shape of the prosthesis has been digitally acquired via a 3D scanner and the CAD models of all the components have been created. Through CT images, 3-dimensional models of the shoulder bones have been reconstructed and assembled with the prosthesis components. Numerical FEM models have been set up in order to evaluate how the abduction force changes depending on the humeral tray offset. Using the virtual prototypes of the shoulder-prosthesis assembly, a range of motion analysis has been carried out by setting up a collision detection analysis in a 3D parametric modeling environment. Different humeral tray positions were investigated and four different motions of the arm were simulated. Obtained results have demonstrated that a suitable positioning of the humeral tray can offer significant biomechanical advantages in terms of range of motion and abduction force.

Keywords: CAD , FEM , Reverse engineering , Reverse shoulder prosthesis , Virtual prototyping

In this study, a new method to compare rebuilt surfaces of hulls of sailing yachts is presented. In particular, the considered rebuilt surfaces are created through classic reverse engineering approaches. The new method has been developed by means of Grasshopper, a free generative algorithms editor that can be used as plugin of Rhinoceros, one of the most widespread free-form modelling software. In particular, two different algorithms have been developed: the first one allows controlling the quality of the rebuilt surfaces, the second one, instead, allows to measure the deviations between the original CAD Model and the rebuilt surface of the hull. A case study related to the hull of a small sailing yacht is also presented. The obtained results have demonstrated the efficiency of the new proposed low-cost method.

Keywords: CAD Model , CAE tools , Close range photogrammetry , Generative algorithms , Low-cost reverse engineering analysis , Sailing yacht

Rising reverse engineering applications require the use of 3D models based on polygonal meshes and a set of modeling operations to shape the final product. Usually, 3D modeling tools do not exploit existing software development kits for developing custom virtual applications. This approach can be very useful for reverse engineering process in the medical field. The paper describes the software development of local mesh modeling algorithms as an extension of the open source library VTK with the aim of shaping 3D triangulated meshes. Then, a case study has been considered to create virtual modeling tools supporting the design process of custom-fit products and, in particular, of lower limb prosthetic socket for amputees. The application has been tested to design a socket for a patient with an above knee amputation. Results reached so far provide a positive feedback on the quality of the designed process and outcome, mainly thanks to the use of the virtual tools based on the developed software modules for 3D mesh modeling.

Keywords: medical devices , Polygonal 3D modeling , prosthesis design , VTK

This paper presents a novel instant 3D whole body scanner for healthcare applications. It is based on photogrammetry, a digital technology which allows to reconstruct the surface of objects starting from multiple pictures. The motivation behind this work is the development of minimally invasive procedures for instant data acquisitions of anatomical structure. The scanner provides several features of interests in 3D body scanning technologies for the healthcare domains: (i) instant capture of human body models; (ii) magnitude of accuracy in the order of 1 mm; (iii) simplicity of use; (iv) possibility to scan using different settings; (v) possibility to reconstruct the texture. The system is built upon a modular and distributed architecture. In this paper we highlight its key concepts and the methodology which has led to the current product. We illustrate its potential through one of the most promising 3D scanning healthcare applications: the data acquisition and processing of human body models for the digital manufacturing process of prostheses and orthoses. We validate the overall system in terms of conformity with the the initial requirements.

Keywords: 3D reconstruction , Body scanning , Healthcare , Human body measurements , Human body visualization , Photogrammetry , Proshetics and orthotics

Despite the existence of a wide variety of standards to create hand-made illustrations of lithic artefacts, the conventional process is laborious, time-consuming and the quality of the drawings is highly variable. In this paper, a novel computer-based methodology to create automatic technical documentation of lithic artefacts, in the form of manual-like drawings, is presented. The method exploits the artefact digital model obtained by a 3D optical scanner. An optimization process is proposed to orient the digital model reproducing the conventional positioning. A lighting model is used to introduce an illumination source having different directions, to highlight surface details. A set of images is then created and segmented to retrieve the artefact outline and the internal ridges between flake scars. Potentialities of the proposed methodology are illustrated by analyzing three different stone artefacts acquired by a structured light scanner. 2D technological drawings are automatically created and compared to those obtained by an experienced lithic illustrator.

Keywords: 3D scanning , Automatic technical drawing , Lithic artefact , Reverse engineering

The present paper describes the development and characterization of a structured light stereo catadioptric scanner for the omnidirectional reconstruction of internal surfaces. The proposed approach integrates two digital cameras, a multimedia projector and a spherical mirror, which is used to project the structured light patterns generated by the light emitter and, at the same time, to reflect into the cameras the modulated fringe patterns diffused from the target surface. The adopted optical setup defines a non-central catadioptric system, thus relaxing any geometrical constraint in the relative placement between optical devices. An analytical solution for the reflection on a spherical surface is proposed with the aim at modelling forward and backward projection tasks for a non-central catadioptric setup. The feasibility of the proposed active catadioptric scanner has been verified by reconstructing various target surfaces. Results demonstrated a great influence of the target surface distance from the mirror's centre on the measurement accuracy. The adopted optical configuration allows the definition of a metrological 3D scanner for surfaces disposed within 120 mm from the mirror centre.

Keywords: Catadioptric system , Reverse engineering , Spherical mirror , Structured light stereo system

The manual drafting of lithics artefacts could be a very time-consuming work, and it could be cumbersome on the archaeological site. In this case, a 3D digital model of the object could be very useful. Nowadays, several digitizing technologies are available to easily acquire information about the shape of an object. Virtual models could be used to create a digital museum or to share information between researchers. On the other hand, the manual drafting of a lithic object contains information about the technologies used to realize it. Information about the core setup, types of chipping surfaces, detach sequence of supports, and much more. In this work a method to easily obtain a hand-made-like draft of lithic artefacts is proposed. The method is based on the 3D acquisition of the object with a structured-light based scanner and a sequence of digital processing of the acquired data.

A 3D full-field optical system for high frequency vibration measurement is proposed. The system is composed of a single low-frame-rate camera and two planar mirrors. This compact optical setup overcomes the typical drawback of capturing synchronous acquisitions in the case of a camera pair. Moreover, planar mirrors allow for the use of the classical pinhole model and, thus, conventional stereo-calibration techniques. The use of a low-frame-rate camera provides on the one hand a high-resolution sensor with a relatively low-cost hardware but imposes, on the other, the adoption of a down-sampling approach, which is applicable only when a single (known) sinusoidal load is applied to the structure. The effectiveness of the proposed setup has been verified by the 3D vibration measurement of two different targets up to a frequency of 1 kHz, corresponding to a displacement amplitude of 0.01 mm.

Keywords: digital image correlation , down-sampling approach , Reverse engineering , single low-speed camera

In the computer vision field, the reconstruction of target surfaces is usually achieved by using 3D optical scanners assembled integrating digital cameras and light emitters. However, these solutions are limited by the low field of view, which requires multiple acquisition from different views to reconstruct complex free-form geometries. The combination of mirrors and lenses (catadioptric systems) can be adopted to overcome this issue. In this work, a stereo catadioptric optical scanner has been developed by assembling two digital cameras, a spherical mirror and a multimedia white light projector. The adopted configuration defines a non-single viewpoint system, thus a non-central catadioptric camera model has been developed. An analytical solution to compute the projection of a scene point onto the image plane (forward projection) and vice-versa (backward projection) is presented. The proposed optical setup allows omnidirectional stereo vision thus allowing the reconstruction of target surfaces with a single acquisition. Preliminary results, obtained measuring a hollow specimen, demonstrated the effectiveness of the described approach.

Keywords: 3D acquisition , catadioptric stereo vision system , internal geometries acquisition , spherical mirror projection model , structured light scanning

Background: Current approaches to quantifying the severity of pectus excavatum require internal measurements based on cross-sectional imaging. The aim of this study is to exploit a novel index evaluated on the external surface of the chest with a three-dimensional (3D) optical scanner. Methods: Fifty-one children (41 male, 10 female) between 2 and 17 years of age were evaluated with a 3D optical scanner. Pectus excavatum severity was calculated by using an ad hoc instant 3D scanner and defining an automatic procedure to generate an optical 3D correction index (CI3D). For the latter, an ideal threshold was derived from a statistical analysis, and five blind surveys were collected from pediatric specialists on chest wall deformities. The CI3D was then correlated with blind clinical assessments of PE severity. Results: The cutoff thresholds were determined to optimally discriminate between six degrees of severity of PE patients by a correlation analysis. The correlation coefficient obtained by matching the CI3D with the average subjective severity shows that the proposed method outperforms traditional approaches. Conclusions: The optical 3D index has a good match with the average subjective assessment in distinguishing patients with mild to severe PE. This innovative approach offers several advantages over existing indices, as it is repeatable and does not require cross-sectional imaging. The index might be particularly suitable for monitoring the efficacy of nonoperative treatment and, in the future, for designing an optimal personalized usage of therapeutic devices.

Reverse Engineering (RE) is a long-term goal of engineering and computer science; it aims at the reconstruction of CAD models from measured data by means of 3D mathematical surfaces and geometrical features representing the geometry of a physical part. In the last two decades, reviews and surveys have occasionally covered this topic, but a systematic dissertation of modeling methods from a mechanical engineering point of view is still missing. The purpose of this paper is to fill this gap; starting from a general description of the overall RE framework (acquisition, segmentation, classification, fitting), both an up-to-date survey and a categorization of available modeling techniques and tools working on 3D data are provided. The main aspects of various strategies are discussed as well, in order to highlight strengths and weaknesses characterizing different approaches. Moreover, an overview of commercial software for RE is presented, considering both dedicated solutions and packages supplied as add-on with ‘traditional' CAD systems. Finally, possible improvements to be addressed by the research in the RE field are discussed, outlining potential future trends that are still to be investigated.

Keywords: 3D modeling , CAD reconstruction , constrained fitting , Reverse engineering , reverse engineering software

Template-Based reverse engineering approaches represent a relatively poorly explored strategy in the field of CAD reconstruction from polygonal models. Inspired by recent works suggesting the possibility/opportunity of exploiting a parametric description (i.e. CAD template) of the object to be reconstructed in order to retrieve a meaningful digital representation, a novel reverse engineering approach for the reconstruction of CAD models starting from 3D mesh data is proposed. The reconstruction process is performed relying on a CAD template, whose feature tree and geometric constraints are defined according to the a priori information on the physical object. The CAD template is fitted upon the mesh data, optimizing its dimensional parameters and positioning/orientation by means of a particle swarm optimization algorithm. As a result, a parametric CAD model that perfectly fulfils the imposed geometric relations is produced and a feature tree, defining an associative modelling history, is available to the reverse engineer. The proposed implementation exploits a cooperation between a CAD software package (Siemens NX) and a numerical software environment (MATLAB). Five reconstruction tests, covering both synthetic and real-scanned mesh data, are presented and discussed in the manuscript; the results are finally compared with models generated by state of the art reverse engineering software and key aspects to be addressed in future work are hinted at.

Keywords: 3D mesh , CAD reconstruction , CAD template , Constrained fitting , Particle Swarm Optimization , Reverse engineering

Pectus Excavatum, one of the most frequent chest wall deformities, is characterized by a depression of the sternum and costal cartilages. Patients with mild deformities are generally treated conservatively by using the so called Vacuum Bell (VB) i.e. a suction cup to be placed on the patient's sternal region. Three different sizes, as well as a model fitted for young women, of VB are available on the market. Unfortunately, the variability of the surface to be treated, the possible asymmetry of the caved-in area and the prolonged use, can make the device uncomfortable and, in some cases, ineffective for the patient. In order to cope with these issues, the present paper proposes a computer-aided method for customized vacuum bell design to be used by non-expert user, e.g. by medical staff. In particular, the present work entails the development of a system comprising: 1) a dedicated software capable of acquiring the 3D chest geometry - by using a low-cost range sensor, i.e. Kinect v2 - and of processing the point cloud so to generate NURBS surfaces of the chest; 2) a procedural CAD modeling of a personalized VB implemented within Siemens NX 11 CAD environment. Using the devised method, the medical staff is required only to use the 3D scanning system for acquiring the patient chest and to sketch, in a CAD-based interface, the boundary of the area to be treated. Once these tasks are performed, the system automatically builds the personalized VB model, ready to be manufactured.

Keywords: design customization , Procedural CAD modeling , reverse engineering , vacuum bell

Assembled systems composed of flexible components are widely used in mechanics to dampen vibrations and store or dissipate energy. Often, the flexible components of these systems are assembled via non-linear sliding contacts and yielding constraints. Geometric non-linearity along with non-linearity of stiffness, damping and contact pressure between flexible components greatly complicate the dynamic characterization of these assemblies. Therefore, such assemblies are characterised almost exclusively by means of experimental testing. This research analyses how classic ASME and ISO tolerance standards can be used to guarantee and control the conformity of these assembled systems with their functional requirements limiting the number of experimental tests. In particular the dependence of the dynamic behaviour upon functional tolerances is studied for a mechanical tensioner in a chain drive timing system of an internal combustion engine (ICE). The semi empirical methodology is based on displacement measurements and modal analyses. A multibody model with few degrees of freedom (MBM-FDoF) is proposed as the first approximation to reproduce the variability of the dynamic behaviour of the tensioner considering variations in functional tolerances.

Keywords: ASME-ISO tolerance specification , Deformation energy , Multibody model , Reverse engineering , Tensioner

In the field of rehabilitation, the 3D scanning of body parts can be considered a crucial starting point for subsequent 3D model design of customised devices, especially when additive manufacturing techniques are involved in their production. This study experimentally evaluates and identifies appropriate procedures to acquire and process 3D anatomic images of the hand, including fingers, for the design of customised orthoses. Hand scanning is a complex activity and requires solutions capable of solving problematic aspects, such as the difficulty in maintaining the hand in a steady position and the presence of motion artefacts due to involuntary movements. We addressed such issues by considering the use of two different kinds of optical scanning device. The acquisition process has been initially defined based on healthy subjects and then extended to patients affected by pathologies that compromise upper limb functionality. Quality anatomical models were produced thanks to the application of advanced geometry processing technologies for the automated alignment of multiple scans and the removal of artefacts due to involuntary movements. As a result, with distinctive pros and cons, both the proposed combinations of scanning procedures and dedicated geometry processing evidenced their suitability in producing complete and accurate enough 3D models to be exploited for the subsequent design and production of customised hand orthoses in a typical reverse engineering pipeline.

Keywords: 3D hand scanning , 3D optical scanners , geometry processing , hand orthotics , medical device customisation , reverse engineering

Ancient bronze statues mainly require material integrity assessment and restoration. Restoration may include also the update of the museum exhibition, defining new structural frames and fragment re-composition to preserve the statue and improve the interpretation of the original aspect. This paper proves how engineering methods (such as Finite Element Analysis, Computer Aided Design modelling, Reverse Engineering) may assist cultural heritage experts and restorers in these tasks. It presents the activities made together with the Museo Nazionale Romano and the Istituto Superiore per la Conservazione e il Restauro, on the so-called "Principe Ellenistico" (Hellenistic Prince). This bronze was found in pieces (body, left arm and right leg), at the end of 19th century during an excavation made in Rome. No visual or reference sources can say its origin and its final posture was defined by restorers at the end of the 19th century according to their hypothesis and studies. In the 20th century, a further restoration was made on the critical areas of the surface, together with some structural improvement of the inner frame. Nowadays, after a review of its position inside the Museum, new experimental and numerical analyses have been carried out to better understand surface weakness and correct left arm positioning.

Within the T-VedO project, financed by Tuscany Region, the Reverse Engineering and Virtual Prototyping Lab team of the Department of Industrial Engineering of Florence (Italy) developed a number of methods for the semiautomatic generation of digital 2.5D models starting from paintings. Once such models are prototyped, they can be used to enhance visually impaired people tactile experience of artworks. Such methods, combined into a systematic procedure, allow to solve most of the typical problems arising when dealing with artistic representation of a painted scene. The present paper presents both an overview of the proposed procedure, including most recent updates, and the results obtained for a selected number of artworks of the Florentine Renaissance.

Keywords: 2.5D models , 3D Reconstruction , CAD