๐ Data publikacji: 04.08.2025
Integrating 3D scanning into additive manufacturing begins with high-quality data capture. Modern handheld LiDAR scanners and stationary laser scanners can capture surface geometry at sub-0.1 mm accuracy. Before scanning, ensure proper calibration: set resolution, frame rate, and sensor sensitivity to match object size and material properties. Use reference targets (retro-reflective markers) for smooth, reflective, or textureless surfaces to improve alignment. ๐
During the scan session, maintain consistent scanning speed and distance from the object to avoid noise and dropouts. Capture overlapping scans from multiple angles—360° around the object—to ensure full surface coverage. Once complete, export raw point clouds (in PLY, E57, or XYZ formats) and import them into processing software such as CloudCompare, Artec Studio, or Geomagic Design X. ๐ค
Initial cleaning is essential. Apply statistical outlier removal to eliminate isolated noise points, and use radius-based filters to discard stray readings from shadows or reflective glints. For large datasets (tens to hundreds of millions of points), downsample using voxel grid filtering at a suitable voxel size (e.g., 0.5–1.0 mm) to reduce file size while preserving detail. Segment the point cloud into logical regions: target geometry, background artifacts, and occluded areas. Label each cluster to streamline further processing. ๐
Next, perform scan alignment. Use pairwise registration with ICP (Iterative Closest Point) to fine-tune overlapping scan pairs, then run global registration across the entire dataset. If reference markers were used, apply marker-based alignment for sub-millimeter precision. Verify alignment by visually inspecting cross-sections and point distance heatmaps—errors should remain under 0.1 mm. Your unified, filtered point cloud is now ready for surface reconstruction. ๐ฏ
Convert the final point cloud into a printable mesh. Poisson Surface Reconstruction is a popular choice for watertight meshes, while Delaunay triangulation offers control over mesh density. Software like MeshLab, Geomagic, or Rhino (with Grasshopper) provides user-friendly interfaces to set octree depth (for Poisson) or maximum edge length (for Delaunay). Aim for a mesh that balances fidelity and file manageability—typically 1–3 million triangles for small to mid-sized objects. ๐ป
Address common mesh defects: holes, non-manifold edges, and self-intersecting faces. Use automated hole-filling tools to close small gaps, and manual patching for larger voids. Apply Laplacian or HC smoothing sparingly to remove scan artifacts without eroding critical features. For functional parts, preserve sharp edges and precise holes; hide smoothing behind feature lines. Retopologize areas with overly dense triangles into uniform, quad-dominant topology if you plan to perform further CAD modifications. ๐ ๏ธ
Before exporting to STL or OBJ, optimize for 3D printing. Split the mesh into build-volume–sized sections if necessary, adding alignment features (dovetail joints or pins) for reassembly. Check wall thickness throughout the model: minimum thickness for FDM printers is about 1 mm, while SLA can handle walls as thin as 0.4 mm. Identify overhangs exceeding 45° and flag them for support generation. Finally, decimate the mesh by 20–40% to reduce file size, while keeping a minimum triangle size around 0.5 mm to maintain detail. ๐๏ธ
Export the optimized mesh to your slicer—Cura, PrusaSlicer, or Simplify3D. Configure layer height (0.1–0.3 mm), infill percentage (10–30% for non-structural parts; up to 100% for strength), print speed, and temperature settings based on material (PLA, PETG, ABS, or resin). Enable tree supports or custom supports for complex features to minimize material usage. Slice in preview mode to inspect each layer, ensuring no errant G-code commands will derail your print. ๐
Transfer the G-code to your 3D printer—FDM, SLA, or SLS. Monitor the initial layers carefully: good bed adhesion and accurate extrusion are critical. Use live-camera monitoring or built-in sensor feedback to detect and pause on failures early. Modern printers with auto-bed leveling and mesh compensation simplify this step. ๐ฅ
Once printing completes, remove supports and perform dimensional checks. Use digital calipers to measure critical features, aiming for a tolerance of ±0.2 mm. If deviations exist, adjust your CAD model or slicer compensation and reprint. For high-precision parts, perform a validation scan and compare the printed model to the original mesh, generating a color-coded deviation map. ๐งช
Mechanical testing follows: tensile or flexural tests for load-bearing components, or fit tests for interlocking assemblies. For functional prototyping, simulate real-world conditions—thermal cycling for automotive parts, chemical exposure for industrial fittings, or biocompatibility assays for medical models. Document all parameters: scan settings, software versions, slicer profiles, and test results in a structured report. ๐
This documentation ensures reproducibility and knowledge transfer. It empowers global teams to replicate the workflow—ideal for distributed manufacturing or service-center repairs. From reverse-engineering legacy components to rapid prototyping new designs, the seamless integration of 3D scanning and printing unlocks unprecedented agility and precision in product development. ๐