The company GTR has built a business that is now firmly established as a leading composite part supplier to the demanding motorsport market.
With regards to ease of use and impressive accuracy, GTR preferred the quality of the point clouds created by the Edge ScanArm HD when scanning.
So the FARO Edge ScanArm has helped GTR to perform a range of non-contact 3D inspection routines and to accurately capture complex and free-form surface data as a detailed 3D point cloud.
When asked about ways to improve racing cars’ performance, Colin Chapman, the founder of the iconic Lotus brand replied. “Simplify, then add lightness”. If he was alive today the innovative designer would be fascinated to see the practical application of his tongue in cheek advice, with the widespread adoption of composites throughout the world of motorsport.
The extraordinary strength to weight ratio of composite materials has enabled F1 and other series to design cars that use semi-monocoque chassis, wings, spoilers, and other parts, made from composites materials that are significantly lighter and stronger. This results in cars that are both faster and safer.
Motorsport’s transition to the use of composites as a preferred material has been aided by a small number of highly specialised companies that have the required levels of composite design and production expertise.
One such concern is GTR, the company’s founders, John Biddlecombe and Simon Kingdon-Butcher, have built a business that is now firmly established as a leading composite part supplier to the demanding motorsport market. In addition GTR now supplies the aerospace, defence, marine and automotive markets.
As many composite parts are manufactured to demanding dimensional tolerances to ensure engineering reliability and best possible aerodynamic characteristics, they present a range of problems to the metrology industry. Not only must measuring equipment exhibit the required levels of accuracy and repeatability, the dynamic nature and the continuous evolution of designs within the F1 and the aerospace market demands speed of inspection and instant data capture
Troy Hull, GTR Quality Manager explained. “Our knowledge of the use of composite within motorsport is second to none. We manufacture everything from chassis, suspension, wing assemblies and bodywork to the smallest of fairings. Now, the vast experience we have gained in this most demanding of areas has enabled GTR to gain contracts for the manufacture of composite components, mouldings and assemblies for other challenging sectors such as the defence, aerospace, automotive and gas and oil industries.
“In addition to the quality of our work, a major factor in GTR’s success is our ability to react quickly to our customers’ needs. Having invested in the best available design systems including Catia V5 and Siemens NX CAD, we are able to rapidly take all projects from concept to fully designed products tooling and on to manufacture. Our first-class production facilities, such as our 3.0M diameter autoclave, one of the five we have on site, and state-of-the-art clean rooms also add to the speed of our service.
“In accordance with our policy of providing our customers with premium quality components as quickly as possible, we recently searched for a measuring technology that would both enhance our accuracy capability and further increase our inspection throughput speed.
“Having looked at several other alternatives, we purchased an Edge ScanArm HD from FARO. In addition to its ease of use and impressive accuracy, we preferred the quality of the point clouds created by the Edge ScanArm HD when scanning. Compared to other systems, the FARO product also performed much better when scanning across a range of materials with different colours and reflective properties.
“Following a short training course, four of our operators were able to quickly understand the Edge ScanArm’s basic operation. Then, as it is so easy to use, they gained further knowledge in everyday use. All are now extremely proficient in the Edge ScanArm’s use.
“We use the FARO Edge ScanArm HD to perform a range of non-contact 3D inspection routines and to accurately capture complex and free-form surface data as a detailed 3D point cloud. We scan a wide variety of components, including items such as 5 meter aerospace wings and F1 gearbox components, down to the smallest of parts. Through the use of our ScanArm we are able to undertake first article inspection and to precisely digitise previously difficult to inspect features such as flush and gap. In addition to being quick and accurate, as FARO laser scanning is so easy to perform, we are able to verifying the most awkward of features and to include their dimensions in 3D documentation and comprehensive, easy to understand inspection reports.
“We also use the FARO Edge ScanArm HD to check components’ complex geometries against design or CAD comparison to ensure that their surface forms remain within tolerance. Additionally, on the rare occasion that no CAD files or drawings exist, we sometimes need to reverse engineer parts. The ScanArm allows us to perform a rapid scanning routine and to digitise a part and create a fully surfaced accurate CAD model for future use.
“Our Edge ScanArm HD has lived-up to each of the promises made by FARO. It has further enhanced our inspection precision levels, speeded-up our measuring routines and vastly improved our component data capture capability.”
The FARO Edge ScanArm HD combines the flexibility and the functionalities of a FARO Edge measuring Arm with the high-definition Laser Line Probe HD creating a powerful contact/non-contact portable measurement system that is ideal for challenging application requirements. It delivers rapid point cloud collection with extreme resolution and high accuracy without the need for any special coatings or target placement – all in a compact and easy-to-use system.
The systems extra wide scan stripe and fast frame rate boosts productivity by increasing coverage and reducing scanning time. Intricate components can be captured in fine detail as a result of the 2,000 actual points per scanline and the new blue laser featuring noise reduction technology. Users are able to dramatically reduce required training time with the new crosshair feature and existing LED Rangefinder functionality, which provides real-time scanning feedback.
The Edge ScanArm HD is a most affordable, high performance contact/non-contact measurement system and is ideal for a wide range of situations, including product development, inspection, and quality control and offers capabilities such as point cloud comparison with CAD, rapid prototyping, reverse engineering, and 3D modelling of free-from surfaces.
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FARO CAM2 Measure 10 is an all-in-one metrology software for users that are looking for a single, complete solution for all tactile measurement and non-contact 3D scanning applications. The software is ideal for CAD and non-CAD inspection and Geometric Dimensioning and Tolerancing (GD&T).
CAM2 Measure 10 features image-guided measurement, automatic nominal association to various features, QuickTools and an intuitive user interface. Moreover, the software is delivered with a reliable CAD import tool which increases the ability to load a large amount of CAD data.
The latest version, CAM2 Measure 10.5 delivers one of its most powerful advantages when scanning large, complex objects.
Its extended point cloud capacity enables you to connect multiple 3D measurement devices to quickly scan large objects. Multi device 3D scanning can – for the first time – occur simultaneously within one coordinate system and input into a single seat of software on one computer.
Simple to set up and use, CAM2 Measure 10 let you leverage the power of simultaneous measurement to complete large scale 3D scanning in a fraction of the time required by conventional methods, allowing you to quickly collect and analyze the data you need to maximize your efficiencies and optimize your processes.
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The Aturia S.p.A. Group, based in Gessate in the province of Milan, is currently one of the leading industrial groups in the pump industry at an international level. The main fields of application are submersible pumps (used in heavy industry and in various segments including shipping, off-shore infrastructure and mining); surface pumps (used, for example, in water supply and heating and air conditioning systems); special pumps (used in reverse osmosis, desalination and cryogenic applications) and, last but not least, pumping units used in firefighting, in particularly high demand at refineries and in the petrochemical industry.
Andrea Guercilena, Group Quality & Test Manager, explains: “The Aturia Group is able to offer high-tech products thanks to its integrated design, 3D modelling and FEM (finite element method) analysis systems. The production cycle begins with the design phase. With our long-term experience and vast database, we are capable ofdeveloping and manufacturing pumps for special fluids with power values that reach 1,000 kW, pressure values up to 150 bar and temperatures up to 500°C.”
The various phases of the industrial process are completed at the Gessate production facility, which facilitates coordination among the various company departments. Guercilena notes: “The large fleet of numerical control machines and the networked management of project specifications allow operators to easily obtain the required precision.”
Product quality is guaranteed by “full control” over all components. Pump shapes, sizes, tolerances and performance are checked in the testing room using traditional as well as latest generation devices and software. In this regard, the Quality & Test Manager talks about how the Aturia Group has recently managed to take a significant step forward: “As our workloads increased in recent years, we realised that we were not able to quickly carry out measurements and inspections with our fixed coordinate measuring machine, resulting in the risk of delaying deliveries and disappointing our clients. At the same time, we were witnessing an increase in requests for larger than average pumps, which are difficult to measure using traditional methods. Therefore, we decided to invest in a portable 3D measuring machine with a laser line probe, which is considerably more suited to our new requirements.”
As a result, in late 2013 the companypurchased the FARO Edge ScanArm, a complete system consisting of the portable Edge FaroArm and the laser line probe, ideal for contact and noncontact measurements. “We had seen the machine in action in other workshops,” Guercilena continues, “and we were really impressed. In addition, by speaking with external colleagues and technicians, we understood that for our needs there could be no better tool in terms of quality and reliability than the FARO Edge ScanArm.”
The FARO Edge ScanArm is a seven-axis measurement system with an integrated laser scanner, which makes it possible to measure individual points with the sensor and to conduct scans when large volumes of data are required. According to Andrea Guercilena: “The very broad scanning range enabled us to immediately measure parts of any shape and size. The rapid acquisition speed, portability, manageability and ease of use of the FARO instrument also provided a great boost in productivity.”
But that’s not all: thanks to efficient data processing and management and the possibility to immediately generate easy-to-analyse reporting, with the FARO Edge ScanArm scans can be checked in real time. This is a very important feature since, as Guercilena explains, “it allows inspections and checks to be conducted on-site at the premises of clients or certification bodies. This is a very valuable service that guarantees complete security, even for the most demanding users.”
The technical features of the FARO Edge ScanArm provide very accurate, reliable and repeatable measurement data: “Our pumps,” Guercilena continues, “are complex objects with specific, difficult to measure shapes that require accuracy to the hundredth of a millimetre and just as strict concentricity and parallelism tolerances. Thanks to the FARO ScanArm, we have expanded our measurement possibilities and sped up certification and inspection activities. The high-quality scans also allow us to analyse our products in detail and continuously improve them.” Therefore, the introduction of the FARO Edge Scan- Arm triggered a small but significant revolution at Aturia. “Yes, absolutely,” Andrea Guercilena concludes. “The results achieved are attributable to this excellent technology as well as the FARO personnel who, besides providing the training course, fulfilled our needs by passionately and skilfully responding to our specific requests and supporting us during our technological training and development process.”
In addition to large and small casting capabilities, Goldens’ also utilizes a centrifugal casting that is unique in the foundry industry. The process requires a special mix of knowledge, practices, and skills that differ greatly from other types of foundry operations. In Goldens’ centrifugal casting process, molten iron is poured into a hollow cylindrical mold spinning on a horizontal or vertical axis at speeds generating 40 to 70 Gs of centrifugal force. This force distributes the molten metal, promotes directional solidification, and improves casting integrity by forcing impurities to the inside surface. When the casting has cooled, it is removed from the mold. Castings may be machined in follow-up with excellent properties.
To ensure these properties, each casting must be inspected. This can present a real problem. The size of a cast can be 40 x 30 x 30 inches and weigh 250 pounds. The bores, bolt holes, threaded holes, milled surfaces, and casted features all need to be measured and verified. This work was previously done using a traditional fixed CMM and hand tools. These methods proved inefficient as the CMM required complicated and even cumbersome set ups. The measurement range of the fixed CMM was not large enough and that created the need for the hand tools. To work around this, parts had to be arranged in multiple setups, often requiring a hoist in order to check the entire part.
“Obviously, this was not a perfect solution with respect to our practice of productivity, efficiency, and eliminating waste,” said Jason Gallahair, an engineer at Goldens’. “To correct, or improve, this process we looked for a more user-friendly and portable system that was scalable to our application while still adhering to our principles of value.”
The complete solution they were looking for was found in the revolutionary FARO Edge ScanArm perfect for Inspection and Reverse Engineering. The Edge is a portable CMM, a measurement arm, with an easily interchangeable contact and non-contact measurement capability. The system allows Goldens’ to check an entire part, on all sides, in one set location. The system reduced the setup time for large, multi-sided parts. The maneuverability of the Edge allows a user to reach all of the needed part features. This kind of flexibility is just not possible with a fixed CMM where you are often met with situations where if you can’t reach a feature, you are required to move the part, re-fixture it, and then measure again.
Return on Investment
“Though there was some scepticism and misunderstanding, at first, in how the FARO Edge was going to be used, now it’s one of the busiest pieces of equipment on our shop floor,” said Josh Shorey, a quality control tech at Goldens’. “After a three-day training class, our users were fully proficient in programming and checking parts with the Edge.” The fast, and easy, setups with the Edge have greatly impacted the overall efficiency of the floor. Total check time for parts that once took 45 minutes and three position changes on a traditional CMM, are now done in only 2 and half minutes using the FARO Edge – a reduction of over 90%. “Goldens’ even gained recognition from an important customer by scoring a perfect 100-percent on their metrology capabilities after purchasing their FaroArm,” added Mr. Gallahair. “This customer is a FARO user too.”
The company saved 85 man hours on just one part number in the first six months after implementing FARO into their processes. Goldens’ have seen a reduction in time, an improvement in their processes, and a savings in money – all key components to their overall dedication to continuous improvement.
The FARO Edge ScanArm HD combines the flexibility and the functionalities of a FARO Edge measuring Arm with the high-definition Laser Line Probe HD creating a powerful contact/non-contact portable measurement system ideal for challenging application requirements.
The FARO Edge ScanArm HD delivers rapid point cloud collection with extreme resolution and high accuracy without any special coatings or target placement – all in a compact and easy-to-use system.
A short video showcasing the FARO ScanArm and it’s it’s ability to scan a vast spectrum of surfaces ranging from shiny carbon fibre to a mirror finished chrome part, as shown in the video below.
The extra wide scan stripe and fast frame rate boosts productivity by increasing coverage and reducing scanning time. Intricate components can be captured in fine detail as a result of the 2,000 actual points per scanline and the new blue laser featuring noise reduction technology. Users can dramatically reduce required training time with the new crosshair feature and existing LED Rangefinder functionality, which provides real-time scanning feedback.
Our FARO Edge ScanArm HD is the most affordable, high performance contact/non-contact measurement system and is ideal for product development, Inspection, and Quality control and offers capabilities such as point cloud comparison with CAD, rapid prototyping, Reverse engineering, and 3D modeling of free-from surfaces.
Okay, so the question is: what exactly is reverse engineering?
Reverse Engineering is the process of duplicating an existing product without the aid of drawings, documentation, or computer models.
Normally the product designer creates a drawing showing how an object is to be built and then the object is manufactured by following the design drawing.
However, with reverse engineering the steps are inverted and the object is ‘reverse engineered’ to discover its structure, function and operation. Therefore, duplication of the part is enabled by capturing physical dimensions, features and material properties.
The FARO ScanArm is a portable CMM ideally suited for reverse engineering applications. One key advantage of using the ScanArm to inspect is that soft, deformable, and complex shapes can be easily inspected without coming into contact with the part, greatly reducing the risk of damaging the item.
Interested in reading more about reverse engineering and success stories with its use? Download the full white paper here!
When it comes to quality assurance at the automotive supplier Mürdter, nothing is left to chance. Each product is checked with a FARO measuring arm in order to guarantee that only flawless components are distributed to their customers.
Mürdter specialise in metal and plastic processing and every day the development engineers at Mürdter ask themselves the same basic question: How can we make this component even lighter without sacrificing quality?
A skull made of Plexiglas based on a 3D scan…science fiction? Not for the surgeons of the University Medical Centre Hospital in Utrecht, who are using Plexiglas to replace the skull of a woman in desperate need.
The rapid development of 3D-scans and printing is not only opening doors for the manufacturing industry but also are causing a real revolution in the medical world.
The extremely detailed images provided by the 3D scanners lend themselves to a wide range of applications, from plastic surgery to the development of tailor-made prostheses and support for medical research.
Work has begun at the Jersey Museum in St Helier, Jersey to separate 70,000 Celtic coins which were discovered in 2012 by two metal detectorists Richard Miles and Reg Mead.
Valued at between £7million and £14million, the hoard is the world’s largest Celtic coin discovery. Thought to have been buried by a tribe fleeing from Julius Caesar’s army around 50BC, the collection of coins is now being worked on in public view at the Jersey Museum. For the past two years the heritage team have been carefully documenting the coin hoard in preparation for seperating the coins bit-by-bit.
But where does FARO come in?
Archaeologists have been using a FARO Edge ScanArm to scan the coins, in order to create 3D imagery and identify patterns in the coins from thousands of years ago! This means that the surface of the coin collection can be scanned before and during work for documentation purposes.
Due to the importance of this work, the Archaeologists at Jersey Museum must carefully pull the hoard apart one coin at a time. This makes the task extremely difficult and the FARO ScanArm will prove essential in aiding Jersey Heritage in the documentation of the 2,000 or so year old find.
For the full BBC article click here!
This turnkey package is aided greatly by an advanced FARO ScanArm that uses laser and tactile measurement techniques to obtain detailed and high accurate 3D representations of tubes, enabling precise and rapid reverse-engineering. The resulting programs can then be downloaded to British Airways’ new bending machines within minutes.
The all-inclusive Unison solution is based on a semi-manual bender with CNC control and a fully CNC all-electric model, both machines are used extensively throughout the global aerospace industry and able to support a wide range of MRO activities.
The loss of revenue resulting from the grounding of modern aircraft can be astronomical, making fast-turnaround MRO capabilities vital to economic performance.
Unison’s renowned tube bending capability, together with the multiple advantages gained through FARO’s precise measurement and reverse engineering competence will help meet the long-term challenging needs of this vital repair and maintenance workshop.
Unison’s complete measure/program/manufacture MRO package will enable a quick and cost-effective repair of fluid lines on aircraft by reverse engineering parts and then accurately re-creating them in the workshop.
Under the terms of the order from British Airways, Unison is responsible for all aspects of bending machine integration and associated equipment connectivity. As Unison’s Managing Director, Alan Pickering, points out, “This turnkey solution demands tight integration of hardware and software resources to create a seamless production environment for efficient on-demand manufacture of specialist precision parts.
“As FARO is a global leader within the field of portable, precise measurement and is a trusted Unison ‘partner’, we were delighted to include the company’s advanced ScanArm and software as part of this turnkey package. The synergy between the ScanArm’s excellent reverse-engineering capability and Unison’s advanced tube bending machines, results in the perfect all-inclusive package.”
With versatile contact and non-contact measuring capabilities, the innovative ScanArm is ideal for performing rapid reverse-engineering tasks. In addition the popular FARO instrument can utilise CAD overlays to check geometries against design or CAD comparison and evaluate deviations in surface form, ensuring that all inspected parts are manufactured to exact tolerances.
Unison’s proven expertise within the aerospace sector and FARO’s accurate, reliable ScanArm are both guaranteeing a comprehensive package offering for British Airways.
For more information on the FARO ScanArm click here!