Reverse Engineering
From the hand-crafted prototype to the high resolution CAD data model is only a small, yet very precise step: Reverse Engineering by Breuckmann as fast and reliable foundation for production, comparison with original tooling data, or archiving.
PrintScanning and Reverse Engineering of
a TechArt GTstreet Back Bumper
“TechArt Automobildesign GmbH” is a successful
German car design company, creating and manufacturing individually customised cars based on Porsche sport cars.
The product range stretches from the complete car body to the smallest detail in interior and engine tuning.
The prototypes of the car body parts are hand manufactured by Techart designers and made of glass fibre. In order to manufacture the final product from these prototypes, high end digitising techniques are applied by aid of a Breuckmann 3D digitising system.
Project Definition
The object to be measured is the hand shaped back bumper of a TechArt GTStreet.
A model of the new prototype of the bumper is made of glass fibre. In order to create the tools used for serial production of the final product in plastic, a 3D surface model of the bumper is needed.
As it is not possible to create a perfectly symmetrical model of the complete bumper, only one half of the fibre model has been produced. After digitising the model, it will be mirrored by aid of the reverse engineering software, thus generating a perfectly symmetrical back bumper.
The project consists of two main stages. Firstly, the back bumper is digitized by a Breuckmann system. In the second stage, a surface model is created by using the reverse engineering software Rapidform XOR2. This 3D surface model will then be delivered as final result.
Result
In this project, the Breuckmann system delivers a surface file as IGES Standard surface format. Based on this file, TechArt can make further adaptations in the subsequent steps of the design process, and finally produce the tool /mould for serial manufacturing of the back bumper in cooperation with Maucher Formenbau GmbH & Co. KG, a specialist in the tools and moulds industry for plastic products.
The surface model can be compared with the scan data to make sure that the accuracy has not been compromised during the reverse engineering process.
Technical Specification
Digitising System: stereoSCAN 3D
- Measuring system: stereoSCAN 3D
- Field of view: 400 mm
- Feature accuracy: ±25μm
- Resolution of the camera: 2 x 1.4 MPixels
- Light source: 100 Watt halogen lamp
- Working distance: 880 mm
- Weight of the sensor: 5 kg
- Measuring time: <1s
- Certification: VDI/VDE Guideline 2634
- Digitisation Software: Optocat 2007R2 (Breuckmann)
- Reverse Engineering: Rapidform XOR2 (INUS Technology)
Photogrammetry System: AICON DPA Pro
- Digital camera: NIKON D3
- Camera resolution: 12.4 MPixels (4288 x 2848 pixel)
- Date transmission: W-LAN
- Length accuracy according to VDI 2634: ±0,015 mm
Pictures
- Photogrammetry
- Measuring process
- Data evaluation
- Complete 3D digitisation...
- ... with the stereoSCAN.
