Physical Digital Ltd
Our 3D scanning services use the globally-respected GOM measurement system – a system we have been using for over 15 years with great success. Our measurement equipment allows us to scan any object of any size in precise detail, delivering the data in any format you require, so that you can immediately use it to improve your designs and processes for almost any project.
Our 3D scanning services are used for:
- All engineering and manufacturing sectors
- Medical products
- 3D presentations
- Art and archaeology
- Consumer goods
- Virtual reality and more
The GOM 3D optical scanner uses two high resolution digital cameras as the method of data capture. A blue light emitting diode (LED) and digital projector passes a fringe pattern across the surface of the object. Using triangulation principles the sensor accurately measures the divergence and convergence of the pattern, creating a high density point cloud of surface measurements. This highly accurate data can be used for quality inspection or to create 3D CAD models or 2D drawings.
Physical Digital has over a decade of experience providing high quality reverse engineered components and assemblies for analysis and remanufacture.
Reverse engineering is the process of creating a computer aided design (CAD) model from scan data of a physical part or object. This process is sometimes required to convert the measured data, which can consist of millions of individual planar polygons, into models based on geometrical and complex curved surfaces. The process can be divided into 3 categories:
- Geometric - Design Intent
Using the scan data as a guide, key design decisions can be made in order to reproduce a component as it was originally designed. This includes the creation of features and surfaces based on geometric primitives, lines, arcs and optimised splines. Reverse engineering models created using this method ensure geometrical constraint such as perpendicularity and concentricity of features along with exact dimensions and angles and the ability to recreate draft angles and material stock ready for remanufacture. This method is typically used for mechanical components that require machining, manufacturing drawings and tolerances.Geometric models can be created using history based parametric or solid modelling, with the ability to generate 2D manufacturing drawings.
- Freeform - As Manufactured
Components can be reverse engineered exactly as manufactured, using Non-uniform Rational B-splines (NURBS) surfacing to replicate scan data accurately. Applications for this method include organic shapes, human interfacing components, complex shapes for analysis and some cast surfaces.
Freeform surfaces can be used for remanufacture of components and for analysis, including Computational Fluid Dynamics and Finite Element Analysis. A combination of Geometric CAD and NURBS surfaces can be used to create the desired reverse engineering model.
- Hybrid Modelling
Using a combination of geometric and freeform surfaces can provide a powerful method of 3D modelling. Areas of freeform data can be combined with exact geometric surfaces to create a hybrid model. A typical example of this would be the reverse engineering of a cylinder head, which includes freeform cast features, such as water jackets and high tolerance machined areas.
Physical Digital provides a wide range of industry focused quality inspection using the highest accuracy 3D scan data captured using the Gesellschaft für Optische Messtechnik (GOM) optical measurement systems, combined with specialist 3D software. Full quality inspection capabilities are offered, including multiple alignments, full Geometric Dimensioning and Tolerancing functionality, parametric updates, trend analysis, inspection sections, curve and 3D and 2D report creation.
Quality Inspection: Applications
- Inspection of ceramic cores
- Inspection of wax models
- Analysis of shrinkage and warp
- Optimisation of processes
- Control of cooling tunnel systems (EMP)
- Shape and dimension analysis of cast and forged components
Physical Digital uses industry-leading GOM optical scanning systems, software and experience, offering bespoke support within the Aero, Turbine and Power Generation sectors.
We offer measurements across a variety of components, from very small turbine blades to turbine housings and full airframes, as well as voluminous components for digital mock-ups.
The GOM system is used and verified by some of the largest aero and turbine companies in the world.
ABB Turbo systems
Pratt & Whitney
Maintenance and Repair and Overhaul (MRO) are enormous cost factors throughout the entire aero and turbine product cycle. In addition to wear and tear analyses, Physical Digital’s optical measurement technology supports the planning and control of repair work:
- Digital coordinate measurement of damaged/prepared surfaces
- Verification of material deposition
- Inspection of completed repairs
The use of structured light 3D scanners to measure complex geometry can greatly reduce inspection time compared to the traditional use of CMM measurements alongside 100% inspection of all parts. Using the specialist blade inspection module, aerofoil features can be analysed.
- Profile Mean Lines
- Profile Centroid
- Profile Twist
- Flow inlet/exit angles
- Chord Line (Bitangential, Axial, Max)
- Stagger Angles
- Camber angles
- Blade pitch
- Throat area/sectional distances
We can offer:
- Parametric Inspection
- 2D section/Curve analysis
- Batch Inspection
- Trend Analysis
The GOM ATOS ScanBox 5120 offered by Physical Digital provides the industry-leading non-contact 3D scanning system on a project basis, giving access to world class automated measurement services. Ideal for multi-part and high-volume inspection, our automated measurement service using 3D scanning offers huge advances in process stability and traceability. This is complemented by a vast reduction in measurement time and reduction in part cost for our customers looking for larger batch or production capabilities. Automated Inspection
3D scanning offers significant advantages over traditional CMM due to the ability to capture traditional geometry along with high density point cloud which provides vital feedback on freeform and organic features of a component. In recent years the trend towards automated inspection has enabled a greater understanding of manufacturing capabilities.
Giving increased confidence in the automated measurement services and process, Physical Digital is able to provide measurement systems analysis including common industry gauge studies into repeatability and reproducibility of the measurement system, fixture and user. This provides an understanding of the uncertainty within the measurement process for a specific component.
Fixture Design & Process Optimisation
Physical Digital’s team of dedicated CAD engineers enable design optimisation of fixtures to increase process stability and speed up work flows involved in part preparation, loading and measurement. This service offers significant cost and time savings compared to in-house design of fixtures.