Holocreators

How to Reduce the Price of 3D CT Scans to 95 EUR per Part

Swann Rack — Fri, 16 May 2025 10:32:47 +0000

3D Scans with CT for 95 EUR – Here’s How We Do It

We have developed a solution to bring the cost of 3D CT scanning down to just 95 EUR per part while maintaining excellent 3D scan quality. We do this by pooling the parts from multiple customers and scanning them all at once.

In this article, we’ll show you exactly how the process works and what to expect at each stage.

A step-by-step look at the CT scanning workflow.

Preparing for 3D CT Scanning

To demonstrate our cost-saving approach, we’ll use this new game controller as an example. Let’s start by unboxing it and getting it ready for the CT scan.

We’ll use this brand-new game controller to demonstrate our CT scanning process.

To get an accurate 3D CT scan, the object needs to fit within the fixed scan volume. We’ll be using a 25 by 25 by 30 centimeter cardboard box, which is just the right size to fit the game controller perfectly.

Everything we want to scan needs to fit inside this box. Box Size: 25cm*25cm*30cm

Now it’s time to place the box inside the 3D CT scanner. It’s a powerful, high-tech machine that uses X-rays to peer inside objects and create detailed 3D images. Its solid door shuts tight, locking everything in for a safe and to protect the operator from the x-ray radiation.

Putting the box with the game controller into the 3D CT scanning machine.

Inside the CT Scanner

Let’s explore what’s happening inside the CT scanner. On the right side, we have the X-ray emitter. It sends out a powerful beam of X-rays that passes through the object we’re scanning.

The X-ray emitter emits radiation onto the object.

On the opposite side sits the detector, a large sensor that captures the X-rays after they’ve passed through the object.

The detector inside the CT scanner captures the X-rays.

Together, these two components allow us to see inside solid parts and create highly detailed 3D scans.

To make things clearer, we’ve created this simple image. On the right, you see the X-ray emitter; in the center is our box; and on the left, the detector. While the box holds everything in place, it’s completely invisible to the CT scanner.

The setup: emitter on the right, box in the middle, detector on the left.

We’ve placed our game controller inside the box. The CT scan will capture every detail of the object inside, but the box itself will remain invisible.

Only the object inside the box, not the box itself appears in the 3D scan.

Controlling the Resolution Through Placement

Once we power on the emitter, it emits a steady X-ray beam toward the detector. The beam’s spread stays fixed, but we can slide the box between the emitter and the detector.

We can move the box between the emitter and the detector to control the 3D scan resolution.

Since the game controller is relatively small, we can position it very close to the X-ray emitter. This gives us a large, detailed projection on the detector, that’s perfect for capturing an ultra-high-resolution 3D scan. Increasing the size of the projection on the detector enhances the resolution of the 3D scan.

The catch? A narrow beam means we can only scan one object at a time. While the detail is incredible, the 3D scan is expensive.

Closer placement of the object towards the emitter creates a larger projection and a higher resolution 3D scan.

When we move the box farther from the emitter, the controller’s projection on the detector becomes smaller. That means we’ll get a bit less details but more space inside the 3D scan volume. And that’s where things get exciting – this extra space allows us to scan multiple parts in a single session. Thus lowering the price per 3D scan.

Moving the object further from the emitter makes the beam wider and the object projection smaller, which lowers the resolution of the 3D scan.

Lowering Costs with Multi-Part 3D Scans

Now that the X-ray beam is fully expanded, we can fit multiple game controllers into the box at the same time.

Scanning multiple objects in a single session brings the cost down. The resolution also drops slightly, but the results are still excellent.

With more room in the beam, we can place multiple controllers in one scan session.

Conversion of 3D CT raw data into a 3D model (STL)

After the 3D CT scan is complete, we get a preview of the 3D CT raw data. Using specialized software, we can filter the scan to highlight different materials. At first, we only see the outer box, but with a few adjustments, the parts inside become visible.

Preview of the raw CT scan. Left side before applying filters. Right side with filters.

In the final step, we export the 3D models as STL files. In this case we have created a detailed, exploded view of the game controller.

A look at the 3D model of the game controller.

Affordable CT Scanning for Your Projects

By using this scanning technique, we make CT scanning more affordable without compromising on quality. If you’re working on a project and need precise 3D models, this 3D scanning method is for you.

We offer the 3D CT scan for 95 EUR per part. Would you like us to 3d scan one of your parts? Simply send it our way.

Holocreators provides scanning services and 3D scan to CAD conversion services (STL to STEP). We are dedicated to assisting you with your projects. Feel free to reach out to us at +49 40 481133 or via email at info@holocreators.com

The post How to Reduce the Price of 3D CT Scans to 95 EUR per Part appeared first on Holocreators.

How to 3D-scan people or animals?

Swann Rack — Thu, 12 Nov 2020 21:09:22 +0000

It was very important to us that all devices presented here can capture color as well as geometry. These 3D scanners are available:

3D body scanner
Handheld 3D scanner
Mobile phone camera or DSLR camera

Botspot’s 3D body scanner

3D Scanning People and Animals with a 3D Body Scanner

The 3D body scanner is the most common and fastest technology to create a 3D model of a person or pet. These are professional devices used mainly in 3D-figure studios. The person to be scanned stands in the middle of the 3D body scanner. This is a circular cabin in which 60 to 120 cameras are mounted. All these cameras are focused on the person that stands needs to be 3D-scanned and trigger simultaneously. The person is photographed from many different perspectives. All these photos are processed into a 3D model using photogrammetry software.

The Advantages of the 3D Body Scanner

One of the biggest advantages of the 3D body scanner is its speed. Especially when taking pictures of children or animals, the problem is that it’s very difficult to keep them still—which is very important. Because the body scanner creates the image in a split second, this type of 3D scanner is often the only way to capture children and animals.

The Disadvantages of the 3D Body Scanner

Due to their size, 3D body scanners are stationary. They are also expensive, costing over 40,000 Euros. A good body scanner, consisting of about 64 DSLR cameras, costs upwards of 100,000 Euros. So, you always have to go to the studio for the 3D scan.

Artec’s Handheld 3D scanner

3D Scanning People and Animals with a Handheld 3D Scanner

A handheld 3D scanner works differently than a 3D body scanner. With a handheld 3D scanner, the object must remain still for about five minutes. The 3D scanner operator slowly walks around the object, and 3D scans it from different angles. The 3D hand scanner can only capture a very small section (approx. 20cm) at a time. Therefore, it takes much more time to 3D scan large objects.

Advantages of the 3D Hand Scanner

The advantages of the hand scanner can be summed up with two words: mobility and cost. Unlike the 3D body scanner, you can take the 3D hand scanner wherever you need to. There are also fewer size restrictions. A body scanner is limited to the interior of the 3D scan cabin for a maximum scan volume. With the handheld 3D scanner, you can scan objects up to the size of a car. A hand scanner is also much cheaper than a body scanner and costs about 15,000 Euros.

Disadvantages of the 3D Handheld Scanner

The biggest disadvantage of the handheld scanner is the time needed for 3D scanning. While the 3D scanner operator walks around the subject, the subject must remain completely still; otherwise, the 3D scanner software cannot create a clean 3D model. You can imagine how difficult this is when working with an animal or a small child. We at Holocreators once tried to 3D scan a horse. While one person tried to keep the horse calm with the bridle, the 3D scanner operator slowly moved the hand scanner around the horse. Unfortunately, the horse’s head kept following the hand scanner thinking it was food. This ruined the 3D scan because, for a successful 3D scan, the object must remain completely still.

iPhone with mobile phone camera

3D Scanning People and Animals with a Mobile Phone Camera or DSLR Camera

We have written a detailed blog post on this topic. Just search for the “Free 3D scanning tutorial” from Holocreators. It is a complete tutorial on how to create a 3D scan with a cell phone or a DSLR camera using free software. Basically, you move the camera around the person you want to 3D scan and take a lot of pictures from different perspectives. The person must stand absolutely still. Afterward, you can use free software to calculate a 3D model from all those pictures. Holocreators has created a FREE 3D Scanning Tutorial showing you how to create a 3D scan with a cell phone or a DSLR camera using free software. Basically, you move the camera around the person you want to 3D scan and take many pictures from different perspectives. The person must stand absolutely still. Afterward, you can use free software to calculate a 3D model from all those pictures.

Advantages of 3D Scanning with a Camera

The biggest advantage is that it is free. You only need a camera and some free software to scan people and animals.

Disadvantages of 3D scanning with a camera

The disadvantage is the low quality of the 3D scan. Also, it’s nearly impossible to have an animal or person stay completely still during the 3D scan. Therefore, artifacts are created in the 3D scan, which must be repaired or retouched afterward.

Do you need a professional 3D scan of a person or your pet?

Holocreators is a 3D scanning company. We offer 3D scanning, 3D scan-to-CAD conversion (STL to STEP) and 3D modeling services. Feel free to reach out to us at +49 40 481133 or via email at info@holocreators.com

The post How to 3D-scan people or animals? appeared first on Holocreators.

What is Kitbashing?

Swann Rack — Wed, 11 Nov 2020 01:01:48 +0000

Model kit of the aircraft “Boeing 737-800”

Kitbashing in Star Wars

The most famous application of kitbashing is found in Star Wars—specifically the first three installments of the movie series—produced in the 70s and 80s. At that time, the use of computers in film production was not as advanced as today. All spaceships were handmade by model makers on the film set. They combined elements from different plastic model kits. Thus, they used the “kitbashing” technique. For that reason, it was possible that the exhaust pipe from a German WWII tank model could be repurposed on the outside of a Star Wars spaceship.

Model spaceship created with kitbashing

Digital Kitbashing and 3D Printing

With the advent of 3D modeling and 3D printing, kitbashing has experienced a renaissance. Instead of combining plastic model kits to create new models, today, people combine multiple parts of 3D models to create something new. They download various 3D models from the internet, from 3Dmodel databases and combine them to design completely new 3D models. The finished 3D model can then be printed on a 3D printer.

Where Do You Find 3D Models for Digital Kitbashing?

The 3D models for kitbashing can be found in 3D-model databases. There are both fee-based and free model databases.

Free 3D-Model Databases

Paid 3D-Model Databases

A model airplane kit of “Westland Whirlwind”

What Software Can Be Used for Digital Kitbashing?

For digital “kitbashing”, it is best to use 3D software to combine multiple 3D models into a new one. It is often necessary to update the topology of the 3D models, which means updating the geometry of the 3D models by “remeshing”. These two programs are particularly well suited for this:

Conclusion

It is very time-consuming to create an entirely new 3D model from scratch. Therefore, it can be helpful to compile a library of 3D models to create new ones from existing 3D models. This digital “kitbashing” is becoming more and more popular. The finished 3D model can then be 3D printed and painted.

Do you need help creating a 3D model using kitbashing?

Holocreators is a 3D scanning company. We offer 3D scanning, 3D scan-to-CAD conversion, and 3D modeling services. Feel free to reach out to us at +49 40 481133 or via email at info@holocreators.com

The post What is Kitbashing? appeared first on Holocreators.

What Types of 3D Model Databases Are Available?

Swann Rack — Thu, 06 Aug 2020 00:35:57 +0000

Free 3D Model Databases

Buy 3D Model Databases

Conclusion

To design a 3D model from scratch is very time-consuming. Therefore, it is great that these 3D model databases exist. Even if you cannot find the 3D model you are looking for, it’s still a good starting point to build upon an existing 3D model or modify it.

Are you looking for a 3d model that can’t be found in any 3D model database?

Holocreators offers 3D scanning services, 3D scan-to-CAD conversion services (STL to STEP), 3D modeling services, and CAD design services. We are happy to support you with your projects. Contact: +49 40 481133 or send an email info@holocreators.com

The post What Types of 3D Model Databases Are Available? appeared first on Holocreators.

What is Reverse Engineering? (Converting a 3D-Scan to CAD)

Swann Rack — Wed, 05 Aug 2020 11:28:31 +0000

Reverse engineering to surface model: 3D scan (left) and NURBS surface model (right)

What Reverse Engineering Methods Are Available?

We distinguish between two different reverse engineering methods. Depending on the shape of the object, the desired accuracy and the project’s intent, we choose one. We have created a video and written a detailed article for every reverse engineering method:

We use reverse engineering to surface model to create a NURBS surface model from a 3D scan. We use reverse engineering to a parametric model if the customer requires a parametric model and access to the entire history tree of a parametric CAD model.

What Software Do You Need for Reverse Engineering?

For converting a 3D scan (STL format) into a CAD model (STEP format), reverse engineering software is needed. Below is a list of reverse engineering programs that are available:

How does Reverse Engineering work?

The original 3D scan (STL format) is loaded into the reverse engineering software. A CAD model (STEP format) is generated by designing it on top of the underlying geometry of the 3D scan.
Depending on the complexity of the shape of the 3D scan, reverse engineering can be performed automatically or manually.

Reverse engineering to parametric model with a history tree: 3D scan (left) and parametric model
(right)

Download Reverse Engineering sample files

For all three reverse engineering methods we have prepared sample files for you to download.

Reverse Engineering to surface model:

Reverse Engineering to parametric model with optional feature tree:

Conclusion

Using these three different reverse engineering techniques, we can convert any 3D scan data into a CAD model. Clean CAD data is often essential for CAD design and manufacturing.

Do you need help with your reverse engineering project?

Holocreators offers professional 3D-scanning and reverse engineering services. If you have any questions about reverse engineering or 3D scanning, don’t hesitate to contact us. We would love to help you with your project. Please call us at +49 40 481133 or send an email info@holocreators.com

The post What is Reverse Engineering? (Converting a 3D-Scan to CAD) appeared first on Holocreators.

What is the difference between NURBs model and a mesh?

Swann Rack — Sun, 02 Aug 2020 10:52:53 +0000

Comparable with Pixel and Vector Graphics

The easiest way to describe the difference between polygon meshes and NURBS models is to compare them to 2D computer graphics:

Graphics on the computer exist either as pixel graphics or as vector graphics. In a pixel graphic, the image consists of many pixels. Each pixel has a specific color. If you enlarge the graphic on the computer and then print it on a large sheet of paper, the image becomes blurred. This is because the individual square pixels have been enlarged, but not the total number of pixels.

There are no pixels in a vector graphic; there are only a few points connected by curves. These curves are recalculated each time the graphic is resized. A vector graphic can thus be enlarged as desired, and a printout will always be razor-sharp.

Meshes Are Like Pixel Graphics and NURBS models Are Like Vector Graphics

In a polygon mesh, the surface is represented by many triangles. If a small polygon mesh is enlarged and printed in 3D, all previously round surfaces of the object will come out of the 3D printer angular.
The polygon mesh does not have enough triangles to create a cleanly curved surface.

Polygon mesh of a stylized sports car. You can download the polygon mesh here.

With NURBS models, enlarging the image is not a problem. Curves define the object’s surface. The curves maintain the object’s perfect shape, no matter how much the 3D model is magnified. The curves are defined by a few control points, and an algorithm recalculates the curves each time the 3D model is resized.

NURBS model of the same stylized sports car. You can download the NURBs model here

Download the example files of a Polygon Mesh and a NURBs model

You can take a look at the difference between a Polygon Mesh and a NURBs model. We have prepared both for you to download. You will need a 3D viewer like Meshlab to look at the STL-file and a CAD Software like FreeCAD to look at the STEP-file.

Conclusion

NURBS 3D models are infinitely scalable without loss of surface quality. Whenever possible, NURBS models are preferred over polygon meshes. However, NURBS models are much more complicated to create and more difficult to edit. Therefore, polygon meshes are used more often.

Do you have any further questions about polygon meshes and NURBS models?

Holocreators offers 3D scanning services, 3D scan-to-CAD conversion services (STL to STEP), 3D modeling services, and CAD design services. We are happy to support you with your projects.Please call us at +49 40 481133 or send an email info@holocreators.com

The post What is the difference between NURBs model and a mesh? appeared first on Holocreators.

Reverse engineering and error propagation

Swann Rack — Sat, 01 Aug 2020 23:56:49 +0000

The original parts A and B fit together like a puzzle

Error Propagation During the 3D Scan

A 3D scan is made of two parts that fit together perfectly like a puzzle. Part A and part B. Our example 3D scanner has an accuracy of ±1 mm. This means that after the 3D scan of part A, the resulting 3D model could be 1 mm larger or smaller than the original. The 3D model of part B could also be 1 mm larger or smaller after the 3D scan. This means in a worst-case scenario, the whole puzzle is shifted by 2 mm and does not fit together properly.

After the 3D Scan, there are deviations between part A and part B

Error Propagation in Reverse Engineering

After the 3D scan, we perform reverse engineering with parametric modeling and a history tree. This has an average deviation of up to ±0.25 mm from the original 3D scan. Adding the deviations of both processes, the puzzle may be off by 2.5 mm.

After reverse engineering, there are even more deviations between A and B

Error Propagation in Manufacturing

During the last step, the 3D model is manufactured with metal 3D printing. Due to manufacturing deviations, the parts may be produced 0.2 mm larger or smaller. In a worst-case scenario, part A and part B now have a combined total deviation of 2.9 mm, and the puzzle pieces no longer fit together.

After production, part A and part B no longer fit together.

Conclusion

It is not possible to eliminate error propagation in reverse engineering, but it can be minimized. At each step of the reverse engineering process, it is important to choose the method that has the least deviation. Therefore, the most accurate 3D-scanning technique should be chosen. And for the reverse engineering process, it is up to the engineer to work as precisely as possible. There are also manufacturing processes that are more precise than others. For example, CNC milling is more accurate than 3D printing.

May we advise you on how to mitigate error propagation with your project?

Holocreators offers professional 3D-scanning and reverse engineering services. We would love to help you with your project and advise you, for example, on how to minimize deviations in your reverse engineering project. Please call us at +49 40 481133 or send an email info@holocreators.com

The post Reverse engineering and error propagation appeared first on Holocreators.

Lecture on reverse engineering (3D scan and CAD)

Swann Rack — Sat, 01 Aug 2020 23:16:45 +0000

The Rapid.Tech and FabCon 3.D Trade Fair in Erfurt

In 2018, the 15th international trade fair and conference “Rapid.Tech” and “FabCon 3.D” took place.
In Erfurt, 5000 visitors and exhibitors from the 3D printing scene came together. Swann Rack explained, to a professional audience, the different steps needed to reverse engineer an object.

Gears as an example project for the presentation on reverse engineering

When 3D scanning an object, you do not immediately get a 3D model that can be 3D-printed, or CNC milled. Instead, you get a point cloud that must be converted to use it inside a CAD software. This conversion process is called “reverse engineering”.

Swann Rack from Holocreators gave a presentation on Reverse Engineering at the Rapid.tech 3D Congress 2018

Step 1: The Creation of the 3D Scan

There are numerous 3D scanning techniques. One is photogrammetry, which is ideal for objects larger than 200 cm. Photogrammetry is not as accurate, but very inexpensive, especially suitable for 3D-scanning larger objects with color. A second 3D scanning technique is structured-light scanning. It >is recommended for parts sized between 5cm and 300cm and achieves very high accuracy to within +/- 0.05 mm. The third technique is CT (computed tomography) 3D scanning. If you want to 3D scan tiny objects with extremely high resolution and precision, then the 3D CT is the best choice.

Audience at Swann Rack’s presentation at the Rapid.tech 3D Congress 2018

Step 2: Reverse Engineering

After 3D-scanning the object, the 3D data needs to be converted into a CAD format—for example, the conversion of an STL file into a STEP file. Reverse engineering can be either an automatic or a manual process. It depends on the application and the quality of the 3D scan. The most complex process is reverse engineering with parametric modeling and a history tree. With this process, the 3D-scan data is manually converted into a CAD format. Manual reconstructions offer maximum functionality because every parameter of the CAD model can later be edited by the customer.

Ticket for the Rapid.Tech and FabCon 3.D Exhibition 2018

Step 3: Manufacturing—3D printing or CNC milling

The final step is manufacturing. Depending on the shape and desired properties of the object, one must choose between, for example, additive manufacturing (3D printing) or CNC milling. The reverse engineering process is complete once the client receives a perfect copy of the original object.

Conclusion

We were delighted to have been given the opportunity to speak about the topics of our daily business at the Rapid.tech 3D Congress. The feedback was very positive, and Swann Rack answered a few questions from the audience after his presentation.

May we assist you with your Reverse Engineering project?

Holocreators offers 3D scanning services, 3D scan-to-CAD conversion services (STL to STEP), 3D modeling services, and CAD design services. We are happy to support you with your projects. Please call us at +49 40 481133 or send an email info@holocreators.com

The post Lecture on reverse engineering (3D scan and CAD) appeared first on Holocreators.

IKEA closet repair with 3D scanning and 3D printing

Swann Rack — Sat, 01 Aug 2020 22:14:34 +0000

3D CT Scan of the Broken Part

This broken clothes rail brace is part of an old IKEA closet. Unfortunately, it did not survive the last
move unscathed. The upper part of the brace was broken, so the rail did not hold anymore.

Broken IKEA clothes rail brace

First, we 3D-scanned the part using 3D CT scanning. For this step, we visited the “Plastics Centre” in
Leipzig, where “Werth’s” brand-new industrial computed tomography 3D scanner is located. The
Tomoscope S works with X-rays. It looks a bit like an oversized microwave and has a lead door to
protect the operator.

Industrial 3D CT scanner from Werth (Tomoscope S)

A 3D CT scan works like this: The X-ray radiation is directed onto the part. The X-rays go through the
object and project an image onto a detector inside the CT Scanner. The part is placed on a turntable
that rotates slowly. This allows the object to be X-rayed from all sides. From these 360° sectional
images, a 3D model can be generated. In the end, the finished 3D scan can be exported in the STL
file format.

Reverse Engineering of the Part

Secondly, we digitally reconstructed the object using software. During this process, we had the
opportunity to repair the faulty part. Thus, we were able to digitally restore the broken corners of
the clothes rail brace to their initial state. “Reverse Engineering” is the technical term for the
conversion from a 3D scan (STL format) into a CAD model (STEP format).

Reverse engineering of the IKEA clothes rail brace

Deviation Analysis

To investigate how far the reverse engineering of the clothes rail braces deviates from the original
3D scan, we created a deviation analysis. For this purpose, we use the free software “Zeiss Inspect”.
The green color indicates that the reconstruction is deviating very little from the original 3D scan.

Deviation Analysis, which compares the 3D Scan against Reverse Engineering. You can download the
deviation analysis here.

3D Printing of the Repaired Part

Next, our repaired clothes rail brace was 3D-printed. There are different 3D printing methods. We
have chosen the laser sintering process (SLS) because it produces very flexible and durable parts.

Industrial 3D printer “Formiga” uses the laser sintering (SLS) method

With the laser sintering process (SLS), on the other hand, the model is built up in a powder bed. The
laser first melts the contours of the object into a thin layer of powder. Then another layer of powder
is applied by a machine, and the laser fuses this layer precisely onto the previous one. This process is
repeated until the entire part is finished. In the finished piece, a fine stair-step pattern is visible;
these are the separation lines between the fused layers.

Removing the 3D-printed Part from the Powder Bed

After 3D printing, the part is inside a powder bed. The finished part must be dug out of this powder.
The surface of the part is sandblasted. Sandblasting smoothes the surface and removes any powder
remnants. In a final step, any remaining dust is blown off.

The repaired clothes rail brace fits perfectly into the closet

Project data for Download

We have provided the deviation analysis and the download link for the Zeiss Inspect software.

Conclusion

The reverse engineering and repair of the clothes rail brace worked wonderfully. The better the 3D
scan of a part, the easier the reverse engineering. In this case, we were able to work based on an
extremely accurate CT 3D scan. Surely this project could have been realized with simpler technology,
but it is an excellent example of what is possible.

Do you have a broken part that you want to repair with 3D scanning and 3D printing?

Holocreators offers 3D scanning services, 3D scan-to-CAD conversion services (STL to STEP), 3D modeling services, and CAD design services. We are happy to support you with your projects. Please call us at +49 40 481133 or send an email info@holocreators.com

The post IKEA closet repair with 3D scanning and 3D printing appeared first on Holocreators.

Deviation analysis (nominal actual comparison)

Swann Rack — Sat, 01 Aug 2020 16:11:21 +0000

Example 1: Deviation Analysis for Quality Control in Production

If a company manufactures metal gears, every day, the factory produces 1000s of gears. Six gears
are taken at random from the production line, and then 3D-scanned. From the time the gear is
initially designed, there is a CAD model. The CAD model is a 3D file with all dimensions of a perfect
gear. This CAD model is compared with the 3D scans from the production line. This is a “nominal
actual comparison”. It is a deviation analysis that shows how much the gears from production
deviate from a perfect gear. Based on this analysis, the engineers can optimize the gear production
machine to improve manufacturing quality.

Gear 3D Scan (left) and gear reverse engineering with solid modeling (right)

Example 2: Deviation Analysis for Quality Control in Reverse Engineering

A part is first 3D-scanned, then a reverse-engineered model is created from this 3d scan. However,
the reverse engineering process can only approximate the 3D scan. The differences between the 3D
scan and the reverse engineering are then analyzed and visualized with a deviation analysis and a
false color comparison.

Front view of a gear; deviation analysis of 3D Scan and CAD model

Deviation Analysis in Four Steps

Import of the nominal data (e.g., CAD file of the perfect gear).
Import of the actual data (e.g., 3D scan of the manufactured gear).
Both data sets are superimposed in the analysis software (Zeiss Inspect)
The data sets are compared, and a deviation analysis report is created. The differences are
visualized with a false color comparison.

Side view of a gear; deviation analysis of 3D Scan and CAD model

Deviation Analysis Report

Two 3D models are superimposed using the analysis software “Zeiss Inspect”. The differences
between the two data sets are displayed in color. Different colors correspond to positive and
negative deviations. On the right side of the report, there is a legend showing a color gradient. Red
means that the actual data is above the nominal data. Blue means that the actual data is below the
nominal data.

Software Zeiss Inspect for creating a deviation analysis or nominal actual comparison report

The best software to create a deviation analysis or nominal actual comparison report is
Zeiss inspect. Zeiss is a company that builds predominantly 3D Scanners but also makes great
software.

Zeiss Inspect (Software for creating a deviation analysis)

Do you require a deviation analysis with your reverse engineering project?

Holocreators offers 3D scanning services, 3D scan-to-CAD conversion services (STL to STEP), 3D modeling services, and CAD design services. We would be happy to assist you with your project. Please call us at +49 40 481133 or send an email info@holocreators.com

The post Deviation analysis (nominal actual comparison) appeared first on Holocreators.