Laser scanning has demonstrated the ability to address all of these challenges. Laser scanning systems work by projecting a line of laser light onto surfaces while built-in arrays continuously triangulate the changing distance and profile of the laser line as it sweeps along, enabling the object to be accurately digitized in 3-D.

The laser probe electronics translate the video image of the line into 3-D coordinates, providing real-time 3-D coordinate data that gives the operator immediate feedback on areas that might have been missed.

Laser scanners are able to quickly measure large parts while generating far greater numbers of data points than mechanical touch probes without the need for templates or fixtures. Since there is no mechanical contact by the laser scanner with the object, the problems of depressing soft objects, measuring small details, capturing complex free-form surfaces are eliminated.

Laser scanners can greatly increase any moldmaker’s RE capa-bilities. First of all, laser scanning takes far less time than a touch digitizer or scanner because—instead of collecting points one by one—the scanner picks up thousands every second. Laser scanning can RE parts that are so complex that they would be practically impossible one point at a time. It’s like the difference between painting with a spray gun and a nailbrush.

Instead of spending days to RE a complicated part, it can now be done in an hour or two. Second, this method produces a far more detailed and accurate point cloud, typically containing several million points that can be used to replicate into CAD models even the most complicated part to demanding tolerances. Laser scanning also does away with other limitations of a digitizer probe such as its inability to accurately define small features or to measure soft parts.

Laser scanners also can improve the process of inspecting prototypes or first articles. Instead of just measuring dimensional lines, laser scanners capture the entire contour of the part. They import the resulting point cloud into software that automatically registers the as-built first article to the CAD model provided by the customers with colorful highlights any differences out of tolerance. RE software provided with the scanner greatly simplifies the process of moving from point cloud to a CAD model, making it possible in minimal time to generate a CAD model of the scanned part that faithfully duplicates the original part.

Laser scanning drastically improves productivity for moldmakers by capturing up to 15,000 points per second, dramatically reducing reverse engineering and inspection time. The ability to capture complete geometries rather than a limited number of points improves accuracy. The non-contact laser probe easily measures free-form shapes, delicate parts and difficult geometries. The quick and simple retrofit is by far the lowest cost way to take advantage of laser scanning technology.