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In recent years, there has been a significant increase in opportunities to create CAD drawings from parts, products, and molds that do not have drawings in the manufacturing process, and to produce prototypes or conduct CAE analysis based on that 3D data. While the creation and modification of such 3D data is an important process, it also imposes a significant workload on the original development tasks. Our company not only offers reverse engineering processes as a contracted service but has also established a system that combines evaluation technology and processing technology to accommodate a wider range of processes. 【Service Features】 ■ Faithfully reproducing external and internal shapes using laser scanners and X-ray CT equipment. ■ Accurate modeling utilizing advanced measurement technology. ■ Producing prototypes using various output methods such as 3D printing, resin molding, and machining.

• Processing Contract
• Prototype Services
• Modeler

The performance of 3D printers has dramatically improved in recent years, and their applications have expanded beyond mere shape verification to include parts for devices and manufacturing process tools. However, there are still many challenges regarding price, speed, and accuracy, and it can be said that they have not yet reached a practical stage. Therefore, our company aims to support the broader utilization of 3D printers by offering services that combine not only modeling services but also the evaluation of printed objects (such as physical property testing and dimensional measurement) and reverse engineering. 【Service Features】 ■ Comprehensive execution of all processes from 3D scanning to modeling, 3D printing, and evaluation. ■ Precise reverse engineering using CT, 3D scanners, and three-dimensional measuring machines. ■ Suggestions for appropriate evaluation methods and conditions for 3D printed objects based on their usage environment and applications.

• 3D Printer
• Processing Contract
• Contract Inspection

In recent years, there has been an increasing demand for shorter lead times and a reduction in the number of prototypes for resin parts, including injection molding. Therefore, our company aims to solve various issues related to the resinization of parts through one-stop support for prototype molding to shorten lead times, reducing the number of prototypes using CAE analysis, and proposals for reverse engineering using X-ray CT equipment and laser scanners. 【Service Features】 - Comprehensive execution of all processes from basic data acquisition to CAE analysis, mold production, molding, and evaluation. - Reduction in the number of prototypes through CAE analysis such as resin flow analysis. - Possibility of resin molding from parts without drawings through reverse engineering. 【Service Examples】 - Prototype molding to change metal parts to resin materials. - Molding trials and dimensional inspections and material property evaluations to consider new molding methods. - Examination of gate positions and molding conditions to reduce voids, sink marks, and warping in molded products. - Dimensional and void inspections of molded products when changing molding conditions or modifying molds. - 3D CAD conversion of molds without drawings.

• Resin mold
• Injection Molding Machine
• Contract manufacturing

When performing reverse engineering, it is necessary to obtain point cloud data of the sample's shape, and the major methods for data acquisition are 3D laser scanning and X-ray CT scanning. Each method has its advantages and disadvantages, but which scanning method offers better accuracy (i.e., higher shape reproducibility)? In this case, we will verify the extent of error and distortion in the scan data from the 3D laser scanner and the X-ray CT scanner based on the dimensions measured by a three-dimensional measuring machine. The procedure is as follows: 【Step 1】 Obtain point cloud data of the sample's shape using a 3D laser scanner. 【Step 2】 Obtain point cloud data of the sample's shape using an X-ray CT scanner. 【Step 3】 Conduct dimensional measurements using a three-dimensional measuring machine. 【Step 4】 Extract dimensional data from the point cloud data in Steps 1 and 2, and compare it with the dimensional data from Step 3.

• Processing Contract
• Contract measurement
• 3D CAD

There are various methods for reverse engineering, and the choice of method affects the output data. Therefore, it is necessary to select the optimal method according to the purpose of data use and required accuracy. We will introduce two methods of reverse engineering based on 3D scan data, along with their procedures and characteristics. <Reverse Engineering Based on Cross-Sectional Contour Shape> [Step 1] Acquisition of shape data (point cloud data) using a laser scanner. [Step 2] Polygonization and mesh correction. [Step 3] Modeling is performed using 3D modeling software and 3D CAD software. A sketch of the cross-section is created on a reference plane, and solid shapes are generated using functions such as extrusion and rotation. <Reverse Engineering Based on Surface Shape> [Step 1] Acquisition of shape data (point cloud data) using a laser scanner. [Step 2] Polygonization and mesh correction. [Step 3] Modeling is performed using 3D modeling software and 3D CAD software. A surface that fits the mesh to the surface shape is created for all surfaces to generate a solid shape.

• Processing Contract
• Contract measurement
• 3D CAD

Commonly used methods for obtaining point cloud data for reverse engineering include 3D laser scanners and X-ray CT devices. However, regardless of how precise the equipment used is, an error of approximately ±0.05 to 0.1 mm occurs during data acquisition. Since the scan data is based on these initial errors, it can be said that achieving highly reproducible reverse engineering is nearly impossible. To improve reproducibility, there are methods to correct CAD drawings by incorporating actual measurements using calipers or micrometers, but there are limitations to the shapes and dimensional accuracy that can be measured with small tools. Our company has been providing measurement services using high-precision measuring instruments such as three-dimensional measuring machines and shape measuring machines for many years, enabling us to perform high-precision reverse engineering leveraging our advanced measurement technology. In this blog, we will introduce high-precision reverse engineering methods for simple-shaped workpieces.

• Processing Contract
• Contract measurement
• 3D CAD

We performed a CT scan of the target object (a plastic cup) using an X-ray CT device and attempted to output it with a 3D printer. By simply converting the CT scan data to STL, it is possible to easily perform reverse engineering of parts without drawings. <Process Steps> [Step 1] Scanning the sample with the X-ray CT device. [Step 2] Converting the scan data to STL using VG STUDIO MAX. [Step 3] Checking the state of the mesh and making corrections if there are any issues such as damage. [Step 4] 3D modeling using a resin 3D printer. The material used is ONYX (carbon fiber reinforced nylon).

• Processing Contract
• 3D Printer
• X-ray inspection equipment

By using 3D TIMON for resin flow analysis, it is possible to predict molding defects at the design stage, thereby reducing the number of mold modifications and prototypes, which leads to a shortened development period and cost reduction. The analysis procedure is as follows: 【Step 1】 Mesh the target shape for analysis. (By meshing, the target shape can be represented as a "collection of small simple shapes," allowing for computation on a computer.) 【Step 2】 Set the necessary conditions such as "filling time," "injection pressure," "holding pressure," "holding time," "cooling time," "resin temperature," "mold temperature," and "resin data." 【Step 3】 Start automatic calculations by the computer.

• Injection Molding Machine
• plastic
• Prototype Services