Direct Dimensions, Inc. Blog

Exciting Events and Contests at RAPID 2012

2012-02-06T16:37:00.003-05:00

The RAPID show and 3D Imaging conference is one of the largest events in our industry. Each year they continue to add more amazing sessions, exhibits and even competitions.

In 2010, the show added a contemporary art gallery, specifically for art created using 3D modeling and additive manufacturing. It was such a success that 2012 will mark the third year for the gallery. SME is accepting submissions for the 2012 gallery until February 28th.

Reflecting the ever growing list of fields that utilize 3D design and additive manufacturing, this year RAPID will also feature a 3D Printing Fashion Show. Interested parties can submit their designs until February 28th.

This year will also introduce a new competition for students (both high school and university levels) called the Design for Direct Digital Manufacturing Competition. From the RAPID website:

The 2012 Design for Direct Digital Manufacturing Competition has begun!
Using the capabilities of direct digital manufacturing (DDM), can you and your team develop a new and innovative product?
Can you and your team integrate DDM into a product or subassembly that effectively illustrates the potential impact of additive manufacturing?

If you can answer YES to both questions, this competition is for YOU!

Make sure to check out the above events and, of course, stop by and see Direct Dimensions at RAPID 2012/3D Imaging Conference.

Training Future Users of 3D Technologies

2012-02-02T13:57:00.008-05:00

At Direct Dimensions we're pretty passionate about spreading the word on how 3D scanning and modeling can contribute to numerous industries.

This often results in tours and mini-training sessions with diverse groups that include artists, engineers, business organizations and often students from various disciplines.

Last week we had the opportunity to hold a training class for a group from the Johns Hopkins University School of Medicine. These were students from the Art as Applied to Medicine program who will eventually use 3D scanning and modeling to aid in Ophthalmological Illustration, Medical Sculpture, and Anaplastology (the creation of facial and somato prosthetics).

In the above image Direct Dimensions Modeler Derek LeBrun and JHU Professor Juan Garcia demonstrate various modeling techniques for the class. The skills that these students are learning will one day enable them to help create new faces, fingers, ears and toes for patients.

A great example of what they will be doing is a project that Direct Dimensions worked on with JHU and Juan Garcia where we helped create a new nose for a solider that had been injured in Iraq. Check out the video below to see how 3D techniques and anaplastology changed the life of a soldier.

3D Scan of MLK Memorial Helps Create a Beautiful Commercial

2012-01-23T09:47:00.007-05:00

When VFX firm MassMarket was creating their "Table of Brotherhood" commercial for Chevrolet they needed footage of the new Martin Luther King Jr. Memorial in Washington, DC. The monument however, had not yet been unveiled.

So how could they create the necessary footage when there was nothing to film?

Through the magic of film (and 3D scanning and modeling)!

With our long history of working with scale models and artists' maquettes, Direct Dimensions and our 3D laser scanning technology were the perfect fit to help with this problem.

We scanned and modeled an approximately 4 foot tall scale model of the Memorial. With the file created MassMarket was able to insert an exact digital copy of the final 30 foot monument.

See the final ad below (the 3D model appears at approximately 52 seconds in).

Save the Date: April 27, 2012

2012-01-19T13:32:00.006-05:00

Are you interested in rapid technologies like 3D scanning, printing, and modeling (You wouldn't be reading this blog if you weren't)? If you live in the Mid-Atlantic region then you are in luck!

This year marks the first annual NextGEN-M Rapid Technologies for Make & Manufacture event. This regional manufacturing institute will include panel sessions, short presentations and vendor exhibits all focused on Rapid Technologies for manufacturing.

NextGEN-M will happen on Friday, April 27, 2012 (7:00 am – 4:00 pm) at the Crowne Plaza Hotel, in Timonium, MD. Registration for this event opens on February 1st, 2012.

Stay tuned for more details!

Case Study: Warehouse Renovation

2012-01-11T13:10:00.009-05:00

Struever Bros. Eccles & Rouse is a Baltimore-based developer whose self-described aim is to transform America’s cities, one neighborhood at a time. They have facilitated extensive community restoration and urban growth re-development in cities like Baltimore, Washington DC, Boston, and beyond.

One of their typical restoration projects was the historic Clipper Mill facility in downtown Baltimore. In its day Clipper Mill was one of the largest machine manufacturing shops and foundries in the country. But, of course like so many old urban industrial sites, it lay abandoned and in ruins for decades.

Scanning Clipper Mill: Large-Volume Scanner Captures Large Interior Space

While much of the site and surrounding area has been transformed by Struever over the past 10 years into exciting new commercial and retail spaces, art studios & restaurants, and even residential units, one old building remains undeveloped in its original abandoned state. Known as the Tractor Building, this is the next project slated for redevelopment.

During the restoration planning phase, Struever encountered design challenges that could be solved using cutting-edge 3D laser scanning technologies. In order to take advantage of historic tax credits by maintaining original design elements, complex features such as the large pane windows, structural beams, and complex roof trussing needed to be accurately measured to be incorporated within the new architectural designs. To turn the large open warehouse-like building into the multi-story residential and office space they had envisioned, Struever required a detailed dimensional inspection of the as-built building in order to create the new development plans.

With nearly 15 years of experience with thousands of complex 3D measurement problems of virtually all type and size, Direct Dimensions was up to the task. Direct Dimensions team members Glenn Woodburn and Jon Wood travelled to the Clipper Mill facility with a FARO LS Laser Scanner, a long-range, large-volume spherical scanner that can digitize vast open spaces with precision very quickly. Over the course of a single day, they performed 23 scans of the facility from different positions, each taking about 10 minutes. In order to capture the complex roof truss structures, the portable scanner was mounted inside a lift and raised into the air for some of the scans.

The scanner, mounted on a tripod like a camera, collected raw data in the form of a dense 3D ‘point cloud’ of millions of coordinates of the elements within the facility. In the end, these 3D laser images formed a high-definition survey of the entire building space, a process that could take weeks using conventional survey measurement tools.

Upon returning to the Direct Dimensions facility in Owings Mills, the raw data scans were loaded into PolyWorks software and then coordinated and aligned together to form a single point cloud of the entire space. Even at this initial stage, any measurement can be extracted from any location within the entire facility as if using a virtual tape measure.

In addition, this dense point cloud can quickly be sliced to cut sections at any location to create traditional architectural drawing styles. In order to help with initial planning, the architects worked real-time with our engineers during this initial processing to obtain desired dimensions quickly. This process proved much faster, more accurate, and more comprehensive than the conventional techniques using a long tape or even a single point distance laser – and all with no ladders.

During a second phase of data analysis, Direct Dimensions produced multiple 2D “as-built” drawings from the laser scan data to accurately document the Tractor Building’s exact interior measurements. This drawing package included plan views and elevations with the locations and configuration of the historical structural elements that would remain in the new design for the space. These traditional architectural drawings provide the as-built blueprint for the designers and engineers at Struever to efficiently redevelop the space within the context of the site’s actual structural elements.

Reconstructing Caligula Presentation

2012-01-05T10:49:00.004-05:00

In our holiday newsletter we talked about the amazing reconstructing Caligula sculpture project in which Direct Dimensions scanned and 3D modeled an ancient Roman sculpture to help an international team of experts digitally reconstruct it. It was one of the most popular stories we've ever published!

For those interested in finding out more about this incredible 3D restoration project you can now you can see a powerpoint presentation of the entire process!

3D Digital Restoration of Caligula, by Direct Dimensions

View more presentations from Direct Dimensions, Inc.

Holiday Newsletter

2011-12-20T15:35:00.005-05:00

Direct Dimensions' end of the year gift to you is a newsletter full of fascinating stories (and one recommendation for a newsletter you should be reading).

Reconstructing Caligula: DDI's expert modelers helped a team of international experts collaborate on the reconstruction of an important Roman sculpture by creating an exact digital recreation.

9/11 Memorial of Maryland: We scanned and modeled steel beam artifacts from the WTC North Tower to aid in the design of the recently unveiled 9/11 Memorial of Maryland

Documenting Two Historical Naval Vessels: We demonstrated the power of the Surphaser HSX and FARO Photon 3D laser scanners at the famous USS Constellation and USS Torsk.

Have you subscribed to LiDAR News yet? Direct Dimensions CEO Michael Raphael and many other industry experts provide regular articles to this newsletter and blog. We recommend checking out this excellent 3D industry resource.

New Men in Black 3 Trailer

2011-12-19T13:41:00.002-05:00

The results of our 3D scanning are all over the new MiB3 trailer: actors, costumes, props, vehicles, sets, and locations!

CMSC 2012 - Call for Papers

2011-12-15T12:55:00.005-05:00

Coordinate Metrology Systems Conference: The World's Premier Event for 3D Metrology Technology Professionals

CMSC is holding its 28th annual technical conference and exhibition in New Orleans in July 2012. This technical conference focusing on portable 3D coordinate measurement metrology, provides a professional venue where ideas, concepts and theory flow freely among participants from around the world. Unlike a typical trade show, the focus at CMSC is on education through various technical presentations and workshops. The educational atmosphere encourages attendees to network and learn about the latest innovations in the field of portable 3D industrial measurement technologies and is a great opportunity to share your expertise with your colleagues.

Having attended and participated in CMSC for many years, Michael Raphael, our president, is serving as the coordinator of the CMSC Technical Presentations and Workshops.

You can find the complete details of the call for papers on the CMSC website. In the meantime, if you have any questions, or potential topics for presentations, feel free to contact Michael Raphael at presentations@cmsc.org and see www.cmsc.org for much more.

Project Snapshot: Scanning Giant Teeth

2011-12-12T18:30:00.004-05:00

3D scanning is becoming increasingly popular in the field of dentistry - but this is certainly taking it to a new extreme! Direct Dimensions Modeler Jon Wood scans a giant set of teeth for the University of Maryland Dental school using a Faro Arm with Laser.

Angel Perfume Bottle

2011-11-10T17:18:00.006-05:00

If you watch TV, you've probably seen the new Victoria's Secret commercial for their Angel perfume.

Direct Dimensions had a part to play in bringing the new Angel bottles to your local store shelves. When the manufacturer needed a precise digital model of the wings for the new bottles, they came to us for scanning and modeling.

Scanning a wing with a Faro Laser Scanner and Arm

Polygonal model of wing

New Victoria's Secret Angel bottle with perfect wings!

Project Snapshot: Lyric Opera House of Baltimore

2011-11-07T15:38:00.005-05:00

When renovations began on the Lyric Opera Opera House of Baltimore, Direct Dimensions had the chance to go inside and scan the theater space. We used both a Faro Photon and a to capture the data. This image of the raw scan data is one of our favorites!

Direct Dimensions is on IMDb

2011-09-26T12:09:00.005-05:00

You may have seen our post the other day about scanning the Lincoln Memorial and how that digital model was used in the Night at the Museum sequel but did you know that we have since worked on several films?

Make sure to take a look at our IMDb page to see the other major films that we've been working on at Direct Dimensions!

Case Study: Bringing Lincoln to Life

2011-09-22T14:51:00.003-05:00

Bringing Lincoln to Life in Night at the Museum: Battle of the Smithsonian

The hit family film Night at the Museum: Battle of the Smithsonian has been described as ingenious for bringing to life many famous art and sculpture pieces and animating ‘monumental’ figures in our nation’s capital.

At Direct Dimensions, we had a small part to play in supplying pieces of data and graphics necessary to bring the Lincoln Memorial to life.

In one of the movie’s most inventive scenes, the statue of Abe Lincoln seated within the Lincoln Memorial stands up and walks out of the Memorial and onto the National Mall. After being contacted by Rhythm and Hues Studios, our team re-purposed 3D scans of the Lincoln Memorial already stored in our files to provide this essential digital information to the Oscar Award-winning visual effects studio in the form of a CAD (Computer-Aided Design) model.

Rhythm and Hues Studios then enhanced the digital information with animation for the Abe that is seen and voiced by Hank Azaria within the film.

Direct Dimensions originally scanned the Lincoln Memorial at the request of the U. S. Government in 2001 – just after September 11th – to understand how significant cultural monuments could be reproduced, if necessary. Since then we have captured many other National Monuments including the Liberty Bell and the Tomb of the Unknown Soldier but the Lincoln Memorial is the first that ended up in a movie.

SIGGRAPH 2011

2011-09-19T16:39:00.007-05:00

Last month Direct Dimensions participated in The Studio at SIGGRAPH 2011. President Michael Raphael was a panelist for a round table discussion entitled: Scan, Model, Print.

The above image was compiled from The Studio where in one area participants were scanned and modeled by Direct Dimensions and then could print themselves with some help from the folks at MakerBot.

We look forward to next year!

Direct Dimensions Contributes to 9/11 Memorial of Maryland

2011-09-11T12:23:00.009-05:00

The 68 Marylanders who lost their lives on 9/11 will be honored today when the 9/11 Memorial of Maryland is unveiled in the Baltimore Inner Harbor. The Memorial, designed by Ziger/Snead, incorporates three steel beams from the World Trade Center, three limestone blocks from the west wall of the Pentagon and three black granite pieces representing the Flight 93 site in Shanksville, PA.

The 9/11 Memorial of Maryland is unique among other state memorials in its design; rather than incorporating the artifacts into a new structure or piece of art the designers felt that leaving the beams in their original state offered a powerful and reverent memorial of the event.

One of the first steps in creating the design was documenting the existing condition of the beams. Due to the extensive damage it would be nearly impossible to document them using traditional methods. It was also important that whatever process was used to record the measurements not come into contact with these historically important pieces.

These two factors lead the team at Ziger/Snead to Direct Dimensions to learn about how cutting edge 3D laser scanning and 3D imaging could be used to capture the beams for the purposes of planning and design. Of course, Direct Dimensions' President Michael Raphael and the DDI team of engineers were excited to tackle such a unique 3D scan while also helping a worthy cause.

The Direct Dimensions team ultimately utilized two different scanners to capture the massive and complex steel beams. The Surphaser HSX Spherical Laser scanner and the new handheld Mantis Vision F5 scanner were used to digitally capture the complex artifacts in just a few hours. Both of these scanners were able to capture the exact measurements of the beams without ever touching them.

The data acquired from the scan, in the form of large point clouds, was digitally modeled and delivered to the designers. According to Ziger/Snead the 3D model can be used in a variety of ways including using it for 3D printing a scale model of the beams, using the 3D models for placement on the project site and construction questions, and using it for the design of structural supports and fasteners.

The monument will be officially unveiled today in Baltimore's Inner Harbor.

You can visit the 9/11 Memorial of Maryland project page to learn more about the creation of the memorial.

Case Study: Parametric Snowmobile Engine

2011-09-07T10:43:00.002-05:00

Reverse Engineering an engine to help University of Maryland Terps Racing beat the competition

Every year a select group of students in the Mechanical Engineering program in the A. James Clark School of Engineering at University of Maryland in College Park, MD compete in the Formula SAE (Society of Automotive Engineers) competition. The FSAE competition requires the team of students to design, build, and race their own open cockpit race car.

The University of Maryland team, called Terps Racing, consistently finishes in the top 10 against 80 to 120 other school programs annually. Aiming for a 1st place finish in the upcoming races, the team is experimenting with a new engine design.

The small autocross cars, usually weighing between 300 and 500 pounds, typically run on modified motorcycle engines. But Terps Racing is experimenting with using a snowmobile engine for the upcoming 2011 races.

During the design phase for a new gearbox for this style engine, the students realized they needed a 3D CAD model of their snowmobile engine so that they could accurately design within the tight tolerances necessary to the mounting points.

Terps Racing approached Direct Dimensions for help with creating a dimensionally accurate 3D model of the engine to aid in their design and we were happy to help!

Here is a review of the major steps in this process:

Step 1) Using a combination of FARO's portable CMM arm and laser scanner, Direct Dimensions' engineer Michael Lent digitized the important geometric interface features on the engine. He then captured the complex casting shape with an attached laser line probe. The FARO system was a great fit for this project because it provides both a contact probe for high accuracy geometric features and a non-contact laser scanner for the complex contoured surfaces.

Step 2) By utilizing a variety of software, including PolyWorks, Geomagic, Rapidform and SolidWorks, the Direct Dimensions engineers quickly merged and modeled the 3D digitized data with the laser scanned 'point clouds' into a hybrid of a parametric solid-based feature model with the watertight complex NURBS surfaces. This file is readily usable within CAD software, such as SolidWorks for the re-design effort.

Step 3) This final hybrid model, which offered both the exact representation of the mounting interfaces as well as the accurate contoured cast surfaces was used by Terps Racing to design their 2011 car.

Get a ShapeShot at SIGGRAPH 2011!

2011-07-26T08:11:00.003-05:00

This year at SIGGRAPH the photo booth goes 3D!

Direct Dimensions Inc. will demonstrate the latest version of ShapeShot at SIGGRAPH 2011 in Vancouver. ShapeShot creates a 3D snapshot of your face. Users can share their face with friends via the online ShapeShot Gallery.

Along with the launch of new ShapeShot hardware, we've added an online store to the ShapeShot web site. Users in the ShapeShot gallery can purchase products including jewelry, a bust, and even an Easter Island head customized with their face. Users can access the store through their secure account at www.shapeshot.com.

If you are going to SIGGRAPH, make sure to stop by The Studio to see ShapeShot in action.

Free Sample Data!

2011-07-22T15:57:00.005-05:00

Every now and then we like to provide sample models for our customers and friends to play around with. This sample data is from the Surphaser Laser Scanner: No other 3D scanner produces such high quality dense data so quickly! Download sample data sets – the quality speaks for itself.

A Plethora of Patriotic Projects

2011-07-04T11:10:00.013-05:00

Happy 4th of July!

At Direct Dimensions we've been lucky to have the opportunity to scan many important historical sites, monuments and artifacts in conjunction with the National Park Service and others.

Below is just a sampling of some of our more incredible projects:

The Liberty Bell / The Normandy Liberty Bell - DDI has had the privilege to laser scan Philadelphia's Liberty Bell on numerous occasions. The data we acquired during these scans has been used in several projects, including exact and modified replicas. In 2004, we were commissioned to help create a replica bell without the iconic crack to commemorate the 60th anniversary of the August 6th, 1944 D-Day invasion of Normandy Beach by Allied forces. Following a ceremony in Normandy, where the ringing of the Liberty Bell was heard for the first time in years, the completed bell was returned to the U.S. and now rests in Philadelphia.

The Lincoln Memorial – Two months after 9/11, Direct Dimensions laser scanned portions of the Lincoln Memorial in Washington, DC for historical documentation of the ornate design. We were able to capture the marble sculpture of Abraham Lincoln himself, as well as the columns and engravings surrounding him. The scans were aligned together to produce an integrated digital model of the monument that can be used to exactly reproduce the original model.

The Maryland Statehouse – The Maryland Statehouse, built during the Revolutionary War and still in use today, was the site of George Washington's resignation as the Commander of the Continental Army. When the Statehouse underwent major renovations a few years ago, Direct Dimensions was called in to document the original brick of the Old Senate Chamber, where Washington once stood. The scans were aligned together to produce an integrated digital model of the room that can be used to exactly reproduce the original structure.

3D Animated Political Cartoons – Over the years at Direct Dimensions we have had a lot of fun working with renowned political cartoonist - Kal. We scanned his exaggerated clay sculptures, including George W. Bush, Hillary Clinton and Barack Obama to help him create interactive 3D animated political cartoons.

The Marine Corps War Memorial – The Marine Corps War Memorial, also known as the Iwo Jima Memorial, is located outside the gates of the Arlington National Cemetery. We were asked to 3D laser scan and image this iconic memorial. The final digital model resulting from the scan data can be used to recreate the memorial or even to create smaller replications of this famous image.

Haven't had enough of our patriotic projects? You can read about more below:

Lincoln Life Mask featured project
Walking in Washington's Footsteps Featured Project
Crazy Memorial Featured Project
Tomb of the Unknown Solider Featured Project

Direct Dimensions Invited to Participate in the Studio at SIGGRAPH 2011

2011-06-30T10:52:00.007-05:00

This year Direct Dimensions is excited to be heavily involved in SIGGRAPH 2011 in Vancouver (August 7-11). We have been invited to participate in the "The Studio", a special, hands on area within SIGGRAPH where 3D industry experts and conference attendees use the latest technologies to create new works, experiment, and collaborate.

Direct Dimensions' President Michael Raphael will also be taking part in a round table entitled: Scan – Model – Print: A Roundtable Chat.

Learn more about the Studio here.

3D Scanning Newsletter - June

2011-06-24T08:03:00.007-05:00

In this month's newsletter we officially introduced the amazing Mantis Vision F5 Scanner.

You can read about how the F5 can be used for facility scanning, see a video of the F5 quickly scanning an accident scene, or download a product brochure.

If you haven't signed up for our newsletter yet, you can do so here.

Direct Dimensions Employee Dan Haga Publishes Photography Book

2011-06-22T13:43:00.005-05:00

At Direct Dimensions our employees are multi-talented! Modeler Dan Haga recently published a photography book featuring historic industrial facilities (which he is also an expert at digitally modeling).

Entitled Urban Atrophy, this collection of amazing photographs "...will take you to another world, a surreal dream where all the people just disappeared and left everything behind," says Dan. Urban Atrophy is available now on Amazon.com!

Project Snapshot: Iwo Jima Memorial

2011-05-31T08:19:00.004-05:00

Coming back from the holiday weekend, we thought we'd post an image from a recent project where Direct Dimensions 3D laser scanned and imaged the The Marine Corps War Memorial.

The memorial, also known as the Iwo Jima Memorial, is located outside the gates of the Arlington National Cemetery. The final digital model resulting from the scan data can be used to recreate the memorial or even to create smaller replications of this iconic image.

We'll be talking about this project more in depth in an upcoming newsletter, so if you haven't subscribed to our newsletter make sure to do so!

Case Study: Scanning the Wright Brothers Propeller

2011-05-25T15:50:00.008-05:00

Direct Dimensions’ 3D Laser Scanner Helps Recreate the Wright Brother’s First Flight

In 1903 at Kitty Hawk, the Wright Brothers took the first sustained heavier-than-air flight by a human. Ninety-five years later Direct Dimensions had the once-in-a-lifetime opportunity to laser scan one of the two original propellers from that airplane.

Direct Dimensions had been approached by the Wright Experience, a Virginia company that rebuilds historical airplanes, about recreating the Wright Brother’s first plane for the upcoming centennial celebration. This project would require a reproduction of these propellers, now famous cultural artifacts in two different museums.

The Wright Experience team needed accurate dimensions from one of the original propellers as originally designed by the Wright Brothers. Direct Dimensions was brought in to “reverse engineer” the complex airfoil shape in order to make an accurate digital 3D CAD model. From this data, the original propeller design could be analyzed “virtually” with advanced software to understand its performance, and then also be used to manufacture accurate replicas.

Well in advance of the upcoming December 2003 centennial anniversary celebration of this first flight, DDI engineers, along with our partners at the U.S. Army at Aberdeen Proving Ground, traveled to a major restoration facility for the U.S. Park Service in Harpers Ferry, West Virginia. We brought along what were then the latest 3D scanning technologies - a Silver FARO Arm paired with a Kreon laser line scanner.

This combination of 3D technology and reverse engineering experience proved ideal for this very exciting project. The non-contact laser scanner captured the intricate detail and complex shape of the hand carved wood propeller and then our engineers processed this data into the final digital model.

We’re not sure who was more excited about the project: our engineering team for getting to see the original Wright Bros. propeller, or the Park Service conservation team for getting to see our fancy 3D laser scanner!

There are several reasons why this project was so intriguing for our staff at Direct Dimensions. For one, some of our engineers have an aerospace background and we work regularly on modern airplanes, helicopters, satellites, and missiles - all of which were derived from the Wright Bros. work. It is also interesting since the FaroArm was originally conceived for the measurement of a modern airplane component, called a thrust reverser. The project was also very appealing because Direct Dimensions performs many projects for capturing and documenting historically significant artifacts.

Direct Dimensions continued working with the Wright Experience team for several years and captured a dozen other original Wright Bros. propellers from 1903 thru 1911 in various museums and collections around the country. Most of these propellers were also reverse engineered and remanufactured for other Wright airplane model replicas. In addition, several of these propellers were tested by NASA in modern wind tunnels to understand the performance of these early designs.

Regarding these tests performed by NASA, Michael Raphael, founder of Direct Dimensions and one of the engineers who worked on this project, explains, "As we were told by historians during the project, by 1911 the Wright Bros. essentially perfected the propeller to some 80 percent power efficiency. Today's best propellers produce 85 percent efficiency. So from 1903 thru 1911, the Wright Bros. got it nearly perfect compared to our best engineers and powerful computers today. This is why NASA is trying so hard to figure out how they did it."

Direct Dimensions is proud to have been part of such a historically significant project using what we think will become historically significant technology. Over the years that have followed, we have applied this same type of scanning systems to such famous original objects as the Liberty Bell, the Tomb of the Unknown Soldier, many Matisse and Degas sculptures, and many more. Please visit our website to see a glimpse of this work and also visit the Wright Experience to learn more about the replica Wright Bros. airplanes.

Featured Project - Digitally Preserving the Lincoln Memorial

2011-04-13T08:11:00.004-05:00

Preserving America's National Monuments

In honor of the Civil War Sesquicentennial we'd like to talk about a scan project that we were privileged to participate in: the 3D scanning of the Lincoln Memorial.

A few weeks after September 11, 2001, representatives from the U.S Government approached Direct Dimensions with a very special request. For obvious reasons, various agencies and organizations had suddenly become interested in documenting significant American cultural landmarks, monuments, and structures in case of similar catastrophic events. The group asked Direct Dimensions to demonstrate its developing capabilities for 3D laser scanning and digital modeling and they even offered up the Lincoln Memorial for this effort.

The DDI scanning team mobilized for a planned one day on-site demonstration on a rainy chilly day in late December 2001 for a broad audience that included high ranking officials from the National Park Service, the Smithsonian Institute, the Architect of the Capitol’s office, and the Historic American Buildings Survey.

Using a portable long-range spherical laser scanner mounted on a tripod, they gathered millions of 3D data points from nearly twenty different scan positions focused mostly on the front entrance area of the Lincoln Memorial and the main interior chamber containing the famous sculpture. During each scan, the system captured thousands of XYZ data points per second yielding a real-time 3D picture of the scene with accuracy to about +/-6 millimeters (0.25 inches).

During the next several weeks back at the Direct Dimensions facility in Baltimore, the team processed the raw scan data sets into a 3D mesh model using PolyWorks software. They also incorporated some of the traditional blueprint architectural records provided for the facility. This resulting 3D digital model ultimately included the front steps of the Lincoln Memorial, several of the front columns, elements from the main interior chamber, and of course much of marble Abe Lincoln seated on the marble throne.

To further demonstrate the potential and value of capturing such important artifacts in high definition 3D digital media, Direct Dimensions collaborated with the U.S. Army’s Advanced Digital Manufacturing group at Aberdeen Proving Ground to fabricate a 20-inch long scaled physical reproduction using rapid prototyping, or 3D printing, of this Lincoln Memorial model including the sculpture of Abe Lincoln. Making this physical model demonstrated the ability to not only capture the complex shapes digitally, but also that the artifacts can be reproduced physically using computerized manufacturing technologies.

Direct Dimensions is proud to have performed this project and has continued advancing its capabilities and technologies for accurately capturing such precious artifacts. Please visit our website at www.directdimensions.com to learn more.

The Andy Monument: New Sculpture Based on 3D Scanning and Imaging Unveiled Today in NYC

2011-03-30T08:30:00.016-05:00

(Photo: Konstantin Bojanov/Courtesy of the Public Art Fund)

The Andy Monument, a sculpture of Andy Warhol by artist Rob Pruitt, is being unveiled today in Union Square at the corner of 17th and Broadway.

The 10 foot tall sculpture is a part of the Public Art Fund's exhibitions for 2011. According to Nicholas Baume of the Public Art Fund, "Pruitt’s sculpture adapts and transforms the familiar tradition of classical statuary. The figure is based on a combination of digital scanning of a live model and hand sculpting." To complete that scanning, Pruitt worked with Direct Dimensions to help recreate the spirit of Warhol.

Scanning the Live Model

Mr. Pruitt and a live model traveled to Direct Dimensions office in Owings Mills, MD for a day of scanning with our full arsenal of products, including the ShapeShot 3D Facial Capture System, the Surphaser HSX Laser Scanner, a patch scanner and a Faro arm with laser scanner. Mr. Pruitt directed the shot, dressing and posing the model. In addition to the live model, separate objects such as a shopping bag and Warhol wig were scanned to add detail to the final sculpture.

Raw Scan Data of the Live Model

The digital imaging was completed with Innovmetric's Polyworks software and Zbrush software. Once the individual models were complete, each of the individual elements such as the body, head, hair wig, bag, and camera were combined to create a high resolution 3D model.

With the 3D model from the live scan complete, Direct Dimensions then digitally sculpted Andy Warhol’s face and head in Z-Brush from photographs provided by Mr. Pruitt. The Warhol bust was then digitally stitched to the live scan model to provide the artist with a complete realistic digital recreation of Andy Warhol.

Mr. Pruitt envisioned a stylized presentation of the portrait for his monument. Working with our modelers Mr. Pruitt directed modifications to the pose, facial expression and surface characteristics to achieve his final vision.

Rendering of Final Pose from Multiple Angles

The 3D data was used to help create the final sculpture, which was surface-finished in chrome and will stand on the corner of Broadway and 17th through October 2, 2011.

You can read more about the project on the Public Art Fund's project page.

Free Sample Models! Sample Surphaser 3D Data

2011-03-29T06:57:00.003-05:00

Known for its unsurpassed accuracy, speed, and ease-of-use, the Surphaser is ideal for rapidly capturing as-built objects of mid-range size including cars, planes, military vehicles, boats, monuments, rooms, buildings, and even people! Applications include reverse engineering, quality control, historical preservation, architecture documentation, and forensic reconstruction.

No other 3D laser scanner produces such dense, high-quality data so quickly. Download sample data sets and see - the quality speaks for itself!

Download Four Free Sample Surphaser Models Now!

You can read more about the Surphaser HSX Laser Scanner here.

Pterosaur Launch Animation

2011-03-22T08:43:00.002-05:00

Last week we posted a case study about scanning Pterosaur bones to help research their launch sequence and how they were able to get their massive wings into the air.

Julia Molnar, a graduate student at Johns Hopkins University department of Art as Applied to Medicine, used the 3D data to create an animation of what the launch sequence may have looked like.

The below video is a great example of how 3D laser scanning and imaging is aiding in diverse scientific research on a regular basis.

Case Study: 3D Imaging Brings Dinosaur Bones to Life

2011-03-16T15:08:00.003-05:00

At Direct Dimensions, we love to 3D laser scan important historical treasures. Perhaps one of the oldest items we've gotten our scanners on is a Pterosaur we scanned for Johns Hopkins University.

Pterosaurs, known more commonly as pterodactyls, lived in the late Triassic to the end of the Cretaceous period. Pterosaurs are particularly notable because they are the first known vertebrate creatures to have evolved winged flight and could grow quite large—the largest known pterosaur had a wingspan of about 33 feet. However, because their bones were hollow bones, the skeletons preserved very poorly, as they are often crushed by the weight of sediment. So when you find a good skeleton, there is much to study about these great creatures.

This is what Julia Molnar, a graduate student at Johns Hopkins University department of Art as Applied to Medicine, brought to Direct Dimensions – a set of bone castings from a well preserved pterosaur skeleton. For her masters thesis project, Ms. Molnar was studying the way in which pterosaurs would have taken flight. Very little is known about their launch sequence, and how such an enormous creature could vault into the sky without dragging its giant wings along the ground.

Thus the challenges – digitize the cast pieces, assemble correctly into a complete skeleton, and help formulate the 3D motion sequence for the ancient creature within the computer.

Step 1: Direct Dimensions scanned the castings of the 8-foot pterosaur skeleton with a FARO Arm equipped with the FARO laser line scanner. The FARO laser scanner also collects precise data without ever having to physically contact its target. The fragments were each scanned in two positions—one with the limbs folded inward, as they would have been when the pterosaur was grounded or at rest, and the other with the wings fully extended, as they would have been in flight.

Though there were some difficulties during the scanning process, they did not prove insurmountable. Ms. Molnar described the process: “The scanning was challenging because there were many undercuts, particularly around the ribcage, and the casting is very fragile. I was really impressed with the way they handled the challenges.”

With Molnar helping explain how the components go together, technician Jon Wood created two 3D digital models of the entire pterosaur skeleton - one for each of the two positions: on ground and in flight.

With these completed digital 3D models, Ms. Molnar then created a 3D animation to show the launch movement. Working in a software program called 3D Studio Max, she applied the constraints that paleontologists had previously discovered about pterosaur flight to animate the transition between the closed, resting position and the open flight position. She discovered that pterosaurs very likely had a quadrupedal launch—a two-phase motion that pressed upwards with the hind legs and then followed that with a forward vault motion using its forelimbs. This technique enabled the pterosaur to clear the surface without dragging its wing tips along the ground.

At Direct Dimensions we were thrilled to have used our 3D laser scanning and digital modeling skills to advance the research of this prehistoric creature. We hope to have more projects like this in the future. There are no limits to how we can use our innovative 3D technologies to uncover our world’s most ancient secrets.

CMSC 2011 Abstract Submission Deadline Extended to March 18th

2011-03-08T16:33:00.002-05:00

Abstracts' deadline has been extended to March 18th for the 2011 Coordinate Metrology Systems Conference (CMSC) in Phoenix, Arizona

The Coordinate Metrology Society, the preeminent membership association for measurement professionals, has announced their "Call for Papers" in anticipation of the 2011 Coordinate Metrology Systems Conference (CMSC). The 27th annual event will be held in Phoenix, Arizona from July 25-29, 2011.

Metrology professionals are invited to submit a 500-word abstract for presentations and technical papers covering industry best practices, scientific research and developments, and successful applications of 3D coordinate measurement systems. The CMSC is the only North American conference dedicated solely to users of portable, high-precision measurement technology used to inspect manufactured and assembled components on the factory floor.

Abstract submissions will be peer-reviewed by the Coordinate Metrology Society and considered for presentation at CMSC 2011. The deadline for abstracts has been extended to March 18, 2011. To submit an abstract for CMSC 2011, e-mail Michael Raphael, Technical Presentations Coordinator at presentations@cmsc.org. Guidelines for presentations and technical papers can be downloaded at 2011 CMSC Guidelines.

3D Scans for Oscar Winning Black Swan

2011-02-27T20:58:00.004-05:00

Direct Dimensions scanned and imaged Natalie Portman in 3D for her Oscar winning role in the film, Black Swan.

We scanned the critically acclaimed actress for the latest film by Darren Aronofsky (Director of The Wrestler). Using various 3D imaging technologies, Ms. Portman's face, head, and body were digitally captured and modeled into 3D.

To see how some of our scans were used, check out this video about the film's special effects.

Direct Dimensions Walks in Washington's Footsteps

2011-02-21T17:47:00.006-05:00

In honor of Presidents' Day, we thought we would share George Washington related projects we've worked on.

Over the years, Direct Dimensions has applied our innovative 3D digital technologies and capabilities to aid in the documentation and restoration of several of our nation's most historic sites and artifacts. As we reviewed the list of our projects with historic significance, we noticed that several had a common link: George Washington.

Williamsburg Coffee House

In the summer of 2008, Direct Dimensions visited Williamsburg, Virginia to document the condition of the existing remains of an original ‘coffee house’ that George Washington was known to frequent. This particular coffee house, owned by Richard Charlton during the 1760's, was one of several that had flourished in the area due to their popularity in London and abroad. Coffee houses of that time were known for more than their coffee, tea, and chocolate served to the colonials - they also hosted informal and spirited intellectual conversation. This activity made Charlton's coffee house one of Williamsburg's political and business ‘hotspots’ of the time. In addition to Washington, Thomas Jefferson and Francis Fauquier were often in attendance.

DDI worked with the Colonial Williamsburg Foundation to laser capture what remains of the coffee house’s stone foundation. Of the original structure, only part of the brick foundation and some wooden fragments are still intact. We scanned the exposed foundation and the earthen floor with our Surphaser HSX spherical scanner. This unique scanner captures extremely accurate and high resolution data over a medium-range (2-10 meters). The Surphaser is a non-contact laser scanner so none of the delicate centuries-old foundation was harmed during the data capture process.

The raw 3D ‘point cloud’ data gathered in Williamsburg was then digitally modeled back at the Direct Dimensions facility in Baltimore, Maryland. The final surface mesh model can be used to analyze the archaeological features found at the site. The data will also be used to help plan the reconstruction of the Charlton coffee house, which is to be rebuilt and furnished in the style of an accurate 18th century structure. Once completed, the coffee house will host educational programming and will have the distinction of being the only establishment of the kind in the country.

Valley Forge, PA

Another Washington-related project we have worked on is the scanning of a river bank in Valley Forge, Pennsylvania - the site of the American Continental Army's camp during the American Revolutionary War. George Washington and his men occupied Valley Forge over the winter of 1777, which marked some of the direst times for the colonial army. Washington's men were cold, poorly-fed, ill-equipped, and worn out from a series of long engagements. However, during Washington's time at Valley Forge, the tide of the war began to turn, eventually leading to American independence. Due to its immense historical significance, the site was designated as the Valley Forge National Historical Park in 1976, under management by the U.S. Park Service.

Direct Dimensions was called to Valley Forge in fall 2005 in order to document an approximately one acre site which had begun to erode along a river bank. Over the course of a single day, we took approximately 20 different outdoor scans of the area using the Faro LS laser scanner, which is optimal for large-scale, long-range projects. The river bank was captured using our 3D technology, as well as several high-resolution scans of what was left of a previously undocumented building foundation. The scan data was digitally modeled to create an accurate ‘watertight’ 3D surface mesh. This data was then used to fabricate a physical scale via rapid prototype 3D printing of the foundation. This model was then finished by model makers and displayed at the visitor’s center. Additionally, the data supplied by Direct Dimensions was used by Park Service officials to aid in the excavation of the Valley Forge site.

Maryland State House

Also related to George Washington, in summer 2008, Direct Dimensions performed digital archival work at the Maryland State House in Annapolis, MD. It was in the room known as the “Old Senate Chamber” within the Maryland State House that George Washington submitted his resignation as the Commander of the Continental Army on December 23, 1783. In tribute, a mannequin of George Washington stands at the head of the room, dressed in period clothing and a bronze plaque commemorates the exact spot of this famous transition of power.

The Maryland State House, built during the Revolutionary War, still functions today as the oldest continuously used State House in the nation. Clearly, given the significance of this structure, Direct Dimensions was quite willing to demonstrate the 3D digital capabilities that can be used to document, analyze, and restore its original design.

In one day on-site in Annapolis, DDI laser scanned the entire Old Senate Chamber room, which included its exposed original brick walls, plaster ceiling, wood plank flooring, a small 2nd story balcony, and the architectural ornamental elements. Again the Surphaser mid-range scanner was used as it was the perfect tool to capture all these fine details of the approximate 35-ft square room. In addition, DDI performed several test scans on the State House's unique and famous dome, so significant that it was featured on Maryland’s commemorative state quarter.

The raw laser data, digitally modeled by DDI’s technicians using PolyWorks software, was provided for the Historical Structure Archive for the State. Given its resolution and accuracy, it could also be used to replicate historical elements in exact detail, should the need arise.

More Presidential Projects
If you haven't had your fill of 3D American Presidents, make sure to read our other case studies Presidents Lincoln, Bush and Obama.

Lincoln Memorial Featured Project
Lincoln Life Mask featured project
Virtual Obama featured project

Case Study: Using 3D Laser Scanning to Convert Building into BIM

2011-01-25T11:48:00.000-05:00

Reconstructing Buildings from Physical Facilities into Virtual Realities

In November 2008 Clark Construction and joint venture partner Hunt Construction Group were awarded a contract for building phase IV of the VA Southern Nevada Healthcare System’s new 150-acre medical campus. At $364.9 million, the hospital project was the largest ever awarded by the VA.

Clark Construction is one of the largest general contracting companies in the United States and one of their primary tenets is their commitment to a well planned pre-construction phase. Extra care early on can lead to fewer construction-phase changes, reduced construction time, and cost savings. Their commitment to this principal has led them to embrace many cutting-edge technologies such as Building Information Modeling or BIM.

Associated General Contractors of America define BIM as “an object-oriented building development tool that utilizes 5-D modeling concepts, information technology and software interoperability to design, construct and operate a building project, as well as communicate its details.”

According to Jim Day, Vice President of the Las Vegas Office, in an interview with Business Excellence Magazine, the biggest advantage to BIM is “improved efficiency when you get to the point where you are installing systems.” Pre-BIM, spatial conflicts during installation might not have been detected until systems were being installed; with a Building Information Model these errors (and the time and costs associated with them) can be avoided.

During the construction planning phase for the hospital, the team at Clark encountered design challenges that could be solved using cutting-edge 3D laser scanning technologies. They were interested in including an existing energy plant into their VA Hospital BIM. Rather than attempt to create a model of the plant from scratch, Clark Construction was looking for a company who could document the existing rooms and model them into a format suitable for inclusion in their hospital model.

With over 15 years of experience with thousands of complex 3D measurement problems of virtually all type and size, Direct Dimensions was up to the task. Direct Dimensions team members Glenn Woodburn and Dan Haga flew out to the VA Hospital Site with a Faro LS Laser Scanner, a long-range, large-volume spherical scanner that can digitize vast open spaces with precision very quickly. Over the course of a week, they scanned and documented 10 extensive MEP spaces within the facility from multiple vantage points. These 3D laser scans included all existing facilities and installed components including mechanical, electrical, and plumbing fit-outs, air handling duct work, and structural ladders, catwalks, and platforms.

The scanner, mounted on a tripod like a camera, collected raw data in the form of a dense 3D spherical ‘point cloud’ of millions of coordinates of the elements within the facility. In the end, these 3D laser images formed a high-definition survey of each room, a process that could take weeks using conventional survey measurement tools.

Upon returning to the Direct Dimensions facility in Owings Mills, the raw data scans were loaded into PolyWorks software and then coordinated and aligned together to form single point clouds of each room. Even at this initial stage, measurements can be extracted from any location within the entire facility as if using a virtual tape measure.

After the scans were aligned in PolyWorks, they were brought into Rhino using the Pointools plug-in to create engineered geometry-based models. Then rooms that were spatially related, such as the boiler and chiller rooms, were aligned together for easier inclusion into the final BIM. The final CAD models were exported in DXF format, suitable for importation into NavisWorks, the software package Clark was using to construct the BIM.

Phase IV of the VA Southern Nevada Healthcare System’s new 150-acre medical campus is scheduled to be completed in 2011.

3D Imaging Technologies Webinar for APMM Members

2011-01-17T10:25:00.008-05:00

Direct Dimensions is sponsoring a webinar for APMM this Wednesday, January 19th:
"3D Imaging Technologies to Help the Model Making Process".

There will be two available webinar sessions: 12 & 3 pm EST Wednesday January, 19th. If interested please contact info@modelmakers.org!

3D laser scanning is a vital tool in every craftperson's tool box. Even if you don't use this technology, being aware of its capabilities will equip you to know when to use and who to call for such services and products.

We will discus various 3D imaging and scanning tools and the conversion of collected raw "point cloud" data into high-quality industrial 3D CAD models, for rapid prototyping via additive manufacturing or 5-axis milling.

Join APMM for this educational webinar on 3D imaging as applied to model making!

Free Sample Model!

2011-01-05T10:41:00.003-05:00

Happy New Year!

What better way to start off the year than with a free model download?

You can download the free car model and others on our website.

Everything You Always Wanted to Know . . . Desktop Manufacturing

2010-12-28T08:50:00.002-05:00

Desktop 3D Printers

Welcome to part 2 of this topic- Desktop 3D Printers

Like 3D scanners, 3D printers have already reached the small business market and are now just entering the individual consumer marketplace. Their build envelopes are limited but what could be cooler than printing your own action figures, robot parts, or 3D portraits?

* The RepRap project is an open-source project aimed at creating self replication rapid manufacturing machines. Based out of Bath University, the project shares its plans and the RepRap community can build as is or make their own improvements, which they can then share.

* At the other end of the Desktop 3D printer spectrum comes the V Flash from 3D Systems. Rather than making your 3D printer from scratch you can buy this smaller version of traditional additive manufacturing technology. It is priced for small businesses and schools.

* In the same market space as the V Flash, Solido bills their SolidPro300 as the “world's most cost efficient and flexible 3D printer”. In the US the SolidPro300 is distributed by Enser.

* Between RepRap, the V Flash, and SolidPro300 comes the Makerbot Cupcake CNC. Makerbot sells a kit for the Cupcake CNC but the customer puts it together. Like RepRap, they also host a community called Thingverse. Though their community revolves more around the 3D models than the machine itself. They are also working on a 3D scanning kit.

* HP has also recently announced that they are entering the market in an agreement with Stratysis who will produce mainstream 3D printers using Fused Deposition Modeling technology.

The above examples are just a small selection from a quickly developing marketplace, but they are a good indication of what home scanning technologies are just around the corner. Thanks for reading “Everything you always wanted to know about 3D scanning”, we hope it is has been an informative series!

If you have any questions feel free to contact us at info@dirdim.com.

Everything You Always Wanted to Know . . . Desktop Scanning and Manufacturing

2010-12-20T10:53:00.002-05:00

Chapter 10, Part 1: The Future - Desktop Scanning and Manufacturing

Before we finish our series “Everything you always wanted to know about 3D scanning” we wanted to take a moment to talk about what we think is the immediate future in 3D scanning and manufacturing: the technology is going Desktop.

In the last few years, companies have been creating more products with smaller footprints, at much lower price points, making the technology a viable tool for schools and medium to small businesses. In addition to these new products, students and hobbyists have been creating (and sharing) do-it-yourself versions of 3D scanning and rapid manufacturing products. Soon we could see 3D scanners and printers in home offices!

Coming in the near future – to a home workshop near you!

Commercial Desktop and Handheld Scanners:

There are a few digitizers and scanners out there that are sized and priced for the small business. The price points are not yet for your everyday consumer, but it is getting closer all of the time.

* One of our favorite desktop digitizer/scanners is the Microscribe. It is a miniature articulating arm that is easily portable, is compatible with most popular reverse engineering and metrology packages, and offers near metrology level accuracy in a small package. Obviously you are not going to digitize an airplane with this – but we consider it the first major desktop digitizer (an attachable scanner is also available).
* 3D metrology has also entered the realm of handheld and wireless. eMicroscibe also now offer the MobiGage, the first handheld 3D metrology app. You don’t even need a computer, just a Microscribe and an iPhone or iPod Touch, to take measurements.
* Next Engine also offers a desk top 3D laser scanner. Its compact size, ease of use, customer support and price point are quickly making it a popular choice for small businesses and individuals.

Open Source, Consumer and Up-Coming Scanning Technologies:

While they don’t come close to offering the same kind of accuracy as current available scanning systems, there is a burgeoning community of small businesses, hobbyists and students who are working to bring 3D scanners into the home. New products are rapidly developing.

* Qi Pan, a student at Cambridge University has created ProFORMA, which uses a web cam to collect data and create a color 3D model.
* David Laser Scanner offers a kit to build your own basic scanning system using every day objects like a web cam and hand held laser pointer.
* Perhaps the ultimate in DIY scanners, Friederich Kirschner used Legos, a webcam and some milk to create 3D models.

Stay tuned for part 2 of this chapter- Desktop Manufacturing. If you have any questions about desktop scanning equipment, like the Microscribe, feel free to contact Direct Dimensions. We're happy to answer any questions.

Call for Papers - CMSC

2010-12-17T09:50:00.001-05:00

The Coordinate Metrology Society (CMS), the eminent membership association for measurement professionals, proudly announces the "Call for Papers" for their 2011 Coordinate Metrology Systems Conference (CMSC).

The 27th annual event will be held in Phoenix, AZ from July 25-29, 2011. Metrology professionals from leading manufacturers and science laboratories are invited to submit abstracts for technical papers and presentations covering industry best practices, scientific research and developments, and successful applications of 3D coordinate measurement systems. Abstract submissions will be peer reviewed by the CMS Executive Committee and considered for presentation at CMSC 2011.

Click here for more information.

Case Study: 3D Scanning for Historical Preservation

2010-12-07T11:27:00.002-05:00

Quality Magazine recently ran a story about our 3D scan project for the Maryland Statehouse. You can read the story below.

Archiving the Past

Restoring the original architectural design of The Maryland State House – a Georgian style building built during the Revolutionary War – was made easier with 3-D imaging technology.

In summer 2008, Direct Dimensions Inc. (DDI), a 3-D laser scanning services firm, performed digital archival work at the Maryland State House in Annapolis, MD. The Maryland Statehouse functions today as the oldest continuously used State House in the nation. It was in the room known as the “Old Senate Chamber” within the Maryland State House that George Washington submitted his resignation as the Commander of the Continental Army on December 23, 1783.

A major renovation planned for the Old Senate Chamber, which included removing the plaster walls to show the original brick surface, created a unique opportunity to document the initial structure of this historically important space. With the brick uncovered for only a short period, the archivists wanted to find a way to quickly and accurately document the chamber.

Given the significance of this structure, DDI was quite willing to demonstrate the 3-D digital capabilities that can be used to not only document but also help analyze the existing structure, site plan and even restore the building.

“The archivists had employed a fairly high-tech program, so we were excited to show them our 3-D imaging technologies to help them stay ahead of the curve,” DDI Business Development Manager Harry Abramson explained.

With only one day on-site in Annapolis to document the entire chamber, the DDI engineering team chose the Surphaser HSX medium-range laser for the project. The Surphaser scanner works by sweeping a laser over a specified area. This then returns a high-definition data map of the surfaces touched by the laser. The resulting data can be up to half a billion of points on the surface map, which is shown as a point cloud. This point cloud is used to model an exact digital replica of the scanned structure.

The Surphaser laser scanner was a perfect tool for this project because it was easily portable and able to quickly laser scan the entire Old Senate Chamber room, which included its exposed original brick walls, plaster ceiling, wood plank flooring, a small second story balcony and the architectural ornamental elements. The scanner, mounted on a tripod like a camera, collected raw data in the form of a dense 3-D point cloud of millions of coordinates of the elements within the chamber. In the end, these 3-D laser images formed a high-definition survey of the entire space, a process that could take weeks using conventional measurement tools.

With the scanning complete, the team returned to DDI, where the raw data scans were loaded into PolyWorks software and then coordinated and aligned together to form a single point cloud of the entire space. The point cloud was processed into a digital mesh and surfaced.

The 3-D model of the Old Senate Chamber was provided for the Historical Structure Archive for the State. The model represents a complete digital duplication of this important space. Due to its resolution and accuracy it could also be used to replicate historical elements in exact detail, should the need arise. The same data can also be used to create architectural elevation drawings, 3-D animations and walkthroughs, or even a miniature physical representation.

3D Scanning Newsletter - November

2010-11-30T09:50:00.003-05:00

This month we highlighted some great 3D imaging industry events that are offering the opportunity for you to give back and share your knowledge and expertise with others in our field. We attend, support, and often give technical presentations at these events and always have a wonderful experience!

We also provided a list of some of Direct Dimensions' favorite sites, forums and blogs about 3D scanning.

Thankful in 2010

2010-11-22T15:47:00.008-05:00

Despite the continuing economic challenge, Direct Dimensions has been fortunate to have had another successful year in 2010! This would not have been possible without our wonderful customers, supportive vendors and phenomenal hardworking employees. In the spirit of the Thanksgiving holiday, we would like to express our thanks to everyone who contributed to making 2010 a great year for Direct Dimensions.

Thank you to our customers for trusting us to scan your priceless sculptures, airplanes, historic buildings, inventions and everything else you ask us to 3D digitize for you.

Thank you to our vendors for providing us with the incredible hardware and software products that allow us to scan and model so many types of objects.

And a special thank you to our amazing employees for all of your long hours, dedication, and creativity.

At Direct Dimensions we are also thankful to be part of two rather extraordinary communities that we would like to mention.

Our company is located in Baltimore, which has one of the most vibrant high technology scenes in the entire U.S. In the last year alone we’ve been invited to participate in many technology showcases and events: Betascape, Tech Crawl East, TEDx MidAtlantic, the AME conference and several Greater Baltimore Technology Council (GBTC) events. The leaders and organizers of these events within our local tech community are an amazing and tireless group of people who inspire us on a regular basis with their creativity.

Thank you Baltimore techies for allowing us to be a part of your community!

Our informal 3D imaging families around the world are constantly innovating and supporting each other. We are honored to be part of so many groups that work so hard to educate us all about the remarkable 3D technologies that we all get to play with every day. Our friends and partners at SME, CMSC, SPAR, LiDAR News, and the UK Laser Scanning forum are a huge asset to the entire 3D imaging community.

And of course, thank you for taking the time to read and comment on our newsletters, blog and forum postings, and even our tweets.

Happy Thanksgiving from Direct Dimensions!

Project Snapshot - 3D Skull

2010-11-15T13:35:00.003-05:00

At Direct Dimensions we recently 3D laser scanned this skull. The final digital model can be used for replication, visualization and even analysis.

Everything You Always Wanted to Know . . . Additive Manufacturing

2010-11-09T15:02:00.003-05:00

Chapter 9: From Digital to Physical – Rapid Prototyping and Milling

Up to now we’ve been discussing putting physical objects into the realm of the digital, but before we finish this series we need to talk about another common application for our 3D scanning and modeling processes. Chapter Nine focuses on creating physical objects from digital data.

Important Terminology

Additive Manufacturing – the process of making a physical object from 3D digital data by layering materials; also known as rapid prototyping and 3D printing.

Milling – a subtractive process of removing material to create a physical object directly from 3D digital data by the cutting away from existing solid material.

Applications

You may be asking, why do I need a physical replication of my digital model? After all, we just spent a series of entries talking about turning your physical parts into various digital formats. But there are many good reasons to create new physical models of your data. Here are a few:

* Scaling: Making enlargements, reductions, or even exact size replicas...we can do it all. After a Digital Model has been created, there are few boundaries as to how big or how small we can replicate your object or part.
* Restoration: Our technology enables us to capture accurate 3D data that can be used for manufacturing to completely restore any object that has been damaged by weather, neglect, natural disasters, etc. such as historical monuments and artifacts or aged aircraft and automotive parts.
* Manufacturing Prototype: With a digital model, Direct Dimensions can create a physical prototype that can be used for testing or to manufacture final pieces, such as milling a foam sculpture for a bronze casting pattern or creating a finished prototype as a concept model for a new consumer product.

And now we can talk about the best ways to create the physical models.

Additive Manufacturing (AM)

There are a variety of additive manufacturing equipment manufacturers and processes on the market. Regardless of the type of AM, the various machines read the 3D data most typically in an STL file format. We discussed this format in earlier editions. The software within the machines then generates the layering instructions and directs the deposition of successive layers of material needed to build up the physical part. Essentially this part is created from cross sectional layers. The layers are fused together automatically and ultimately create the final shape, an exact physical replica of the 3D model. Additive manufacturing is an umbrella term that covers many of the following processes.

* One of the earliest and most common types of AM is called Stereolithography (also known as SLA). SLA builds pieces using a laser and a vat of UV-curable liquid resin. Each thin layer of resin is solidified and secured to the layer below with every pass of the UV laser. SLA is good for producing models, patterns, and prototypes. A downside to SLA is that it generally requires support structures to be included in the build, which is part of the SLA process.
* Another AM process is Selective Laser Sintering (also known as SLS). Unlike SLA, SLS can utilize a wide variety of materials such as plastics, metals, and ceramics although post processing may be required. SLS does not require support material while building since it is built and incased within the raw material. SLS uses these materials in a powder format and, by fusing the powder together, creates the layers needed to build the part. SLS is increasingly being used to create final parts for when mass scale production isn’t necessary.
* Similar to Stereolithography is Fused Deposition Modeling (also known as FDM). FDM, trademarked and marketed by Stratasys, also uses the additive platform build concept. Rather than raw liquid or powder, FDM uses thermoplastic materials which are applied through a heated nozzle that places a single thermoplastic bead at a time. These beads fuse together and harden as cooled. The plastics used in FDM are known for their strength and high heat resistance, making them good for product testing.
* Perhaps the most similar to regular 2D printing is the concept of 3D Inkjet Printing. The only rapid prototyping technique that can print in multiple colors, 3D printing also uses a powder base material, but rather than sintering the powder, an inkjet releases a dot of adhesive mixed with coloring, allowing the layers to be built with colors. While the final model is not generally as strong as the other three techniques it is usually cheaper and faster and the colored prints allow for good representation of final concepts. Recently 3D printing has been used commercially to create personalized figurines from World of Warcraft and Rock Band avatar characters.

The primary advantage to additive fabrication is its ability to create almost any shape or geometric feature relatively quickly and inexpensively. We generally say that for a small part, you can’t beat the price to complexity ratio. However the overall volume within a single build is generally limited for AM and for larger parts we recommend milling.

Milling

Milling is best described as a subtractive manufacturing technique. Most often used in the creation of metal production parts, tools, and molds for virtually any industry, an engineer, or even an artist, counts this as a well-tested valuable method. More advanced Computer Numerical Control (CNC) milling machines, like the various additive manufacturing machines, use a 3D CAD file to create a physical reproduction of the digital model. Unlike AM, CNC milling machines can utilize an extremely diverse range of materials including:

* Metals
* Stones
* Woods
* Waxes
* Plastics
* Even Glasses!

Milling steel or aluminum is a common option to make durable tooling. And stone and wood are common for sculpture and historical restoration projects.

Where is this all going?

We are almost done with our “Almost Everything You Always Wanted to Know About 3D Scanning” series. Don’t be surprised if we add additional chapters now and then; the field is constantly changing and growing. We wrap up this series next with talking about the immediate future of these technologies, including desktop (or home) scanning and manufacturing.

3D Scanning Newsletter - October

2010-10-28T10:16:00.003-05:00

This month's 3D Scanning newsletter contains the following stories:

Utilizing 3D Scanning for Historic Preservation: The Druid Hill Arch restoration project is a perfect example of how Direct Dimensions was able to completely document a historical structure in a single day.

Parametric Snowmobile Engine: University of Maryland Terps Racing team needed a snowmobile engine scanned and modeled to help them compete in a 2011 competition

Maryland State House: Unique medium-range 3D laser scanner gathers high accuracy dimensions for historic documentation

If you haven't signed up for our newsletter yet, you can do so here.

Everything You Always Wanted to Know . . 3D Visualizations

2010-10-20T07:48:00.005-05:00

Chapter 8: Using 3D Data for Visualization

While we touched on visualization, one of several downstream applications in Chapter Six, the subject is so comprehensive that it deserves a discussion of its own.

As our lives become increasingly digital and interactive (via the web, video games, and even television and our cell phones), we have come to expect ever more realistic interpretations of real world objects within this virtual realm. One of the best ways to perfect the digital form is to actually copy the shape of objects into 3D via laser scanning and digital imaging.

Visualization applications generally fall into the following categories:

* Animations - 3D digital movies made from computer models
* Renderings - 2D images made from computer models
* Direct 3Dviews - real-time interactive web-based 3D visualizations
* ShapeShot™ - real-time interactive web-based 3D facial images

Animations

When most people think of computer animation they think of the neat special effects in blockbuster movies and the animated explanations of complex events on the nightly news, such as train accidents. Yes - 3D models are frequently used for those types of animations. But often these animations are pure visualizations where the dimensional accuracy of the objects is less important – as long as it looks good.

Our brand of 3D scanning and modeling is more valuable when the quality of the models is critical, such as for museum objects, or military simulations, or for animating highly recognizable objects for tv commercials such as cars. These situations require accuracy and authenticity, which scanning provides, so the objects in the animations look as real as possible. Often real colors and textures are captured and applied to provide that much more realism.

We have created numerous 3D animations from our 3D scanned models for a wide variety of applications including illustrating complex medical procedures, forensic analysis, describing historic preservation sites, and even for Hollywood movies and commercials.

Renderings

Rendering is the process of creating a still image from a 3D model. High quality 2D renderings are often created from an existing 3D model that was originally captured for other purposes. These renderings can be used for graphical presentations, marketing, and even websites. For instance, if a product designer has created a hand-carved physical model for reverse engineering purposes, he can also use that same digital file to create awesome 2D images of his product for marketing graphics. The great thing about a rendering created from a 3D model is that it is highly accurate and quick to render out multiple lighting and background states to create multiple renderings without staging new photography shoots.

Direct 3Dviews

A Direct 3Dview is a fully-interactive real-time 3D presentation of a digital model in a virtual environment. This 3D model visualization can be displayed via a website, a PowerPoint, or even in a stand-alone format. The Direct 3Dview of your object can be used to create an on-line 3D catalog to allow web visitors to fully experience the product - virtually. Another great application is for 3D proofs of concept for a new design or invention in a collaborative viewing environment.

Features of the Direct 3Dview include:

* Smallest viewer on the web - the one-time plug-in is only 130KB
* Smaller digital file sizes = faster download times
* Easily integrates into web sites
* Viewer supported in e-mail as well as PowerPoint
* View file in actual 3D, not a series of images

ShapeShot™

ShapeShots™ are high resolution 3D snapshots of faces that are incredibly life-like. ShapeShot™ enables online personal interaction with amazingly real 3D avatars of you, friends, and family for social networking, online gaming, virtual collaborative environments, and fabrication of personalized consumer products.

New advances in 3D imaging technology have made it to possible to capture faces in a split second and receive an interactive 3D model within minutes with almost no effort.

Direct Dimensions is currently developing the ShapeShot™ concept. See www.shapeshot.com for more information.

From the Virtual to the Physical

The above examples are just a drop in the bucket when it comes to visualization applications. But what happens if you want to take your 3D model and make a physical copy of it? For instance, can you take your Guitar Hero avatar and get a physical 3D copy made? You can, and that process is called Rapid Prototyping or RP. Rapid Prototyping is just one of many technologies that fall into the “3D Printing” category and we’ll be talking about that next.

Case Study: Documenting Ancient Egyptian Artifacts

2010-10-14T16:42:00.003-05:00

Sculptures in ancient Egypt were thought to grant eternal life to the kings, queens, and gods that they portrayed. The mystique of these eternal sculptures is just one of the reasons that we continue to be fascinated by the ancient Egyptian culture and the remarkable sculptures they left behind, many of which remain in museum collections around the world. Many museums consider their Egyptian collection among their most popular exhibits. The Tutankhamen and the Golden Age of Pharaohs, for example, is regarded as the most popular traveling exhibit in history.

Considered one of the finest Ancient Egyptian collections in the world, The University of Pennsylvania’s Museum of Archaeology and Anthropology has over 42,000 items in their collection. Direct Dimensions was approached recently by the University of Pennsylvania museum, known as The University Museum, with an exciting 3D project: the museum officials wanted to offer replicas of some of the most popular pieces for sale in the museum gift shop.

Given the well preserved condition of these original ancient artifacts, and the museums dedication to quality and authenticity, it was important that the replicas be made very precisely to the originals. The officials quickly realized that advanced non-contact 3D imaging technology would be needed to perform this task.

For example, with the age of the sculptures dating back to approximately 1300 B.C., it would not be possible to cast a mold off the pieces as this could damage the originals. Plus it was determined that some of the pieces would need to be reproduced smaller and larger than the originals, so direct casting would not work.

After preparing for the on-site effort at the museum, the DDI technicians scanned four different sculptures: the Amun, the Headless Princess, the Scribe, and a Kneeling King Tut. An articulating arm-based laser line scanner provided high accuracy and real-time feedback to assure complete capture before heading back to Baltimore to process the raw scan data.

For the post-processing, we used Innovmetric’s PolyWorks Modeler software to create highly accurate watertight 3D digital models of each of the ancient pieces. During both the scanning and modeling processes, specific attention was paid to fine cracks and other imperfections in the original pieces – qualities that would make the reproductions that much more accurate and realistic. Some of the models were also scaled to several different heights so that the gift shop could offer the reproductions at different price points.

The final digital models were formatted into STL files and fabricated using rapid prototyping to create high quality patterns. Then the museum arranged for a production fabricator to cast the reproductions in a high quality resin material.

The museum-quality reproduction sculptures are some of the most popular items in their gift shop and visitors are thrilled to bring a little piece of Ancient Egypt home with them.

If you are interested in purchasing a replication, you can call 215-898-4046.

If you would like to make museum-quality reproductions to raise funds for your museum, please contact Direct Dimensions.

ShapeShot at GBTC TechNite tonight!

2010-10-07T10:43:00.004-05:00

Recently at Direct Dimensions, we've been gearing up to show off our new ShapeShotTM concept for GBTC Technite 2010 and the Hottest Tech in Town competition.

Technite is a wonderful annual event held by the Greater Baltimore Technology Council that highlights all of the amazing work tech companies are doing in Baltimore.

This year they are also holding the "Hottest Tech in Town" competition where fifteen technology start-up finalists were chosen from an applicant pool of over forty-five applicants. The ultimate winner will be chosen by a combination of internet voting and a judges panel.

Direct Dimensions, showcasing our ShapeShotTM Technology, is excited to be one of the finalists. The event is tonight and voting continues until 6:30pm. Vote for Direct Dimensions HERE.

If you are attending TechNite this evening, make sure and stop by and get your ShapeShot. We are also launching a new app for Android so you can have your ShapeShot in your hand within 2 minutes!

Check out this video, made by Direct Dimensions Engineer Greg Chaprnka, showing the incredibly realistic and incredibly fast ShapeShot process.

ShapeShot at Tech Crawl East

2010-09-16T12:20:00.004-05:00

Are you intrigued by the idea of seeing a virtual 3D copy of yourself? If so, then you should definitely stop by Tech Crawl East in Baltimore tonight. The event is being held this evening from 5-9 pm on the first floor of the new Morgan Stanley Building in Fells Point.

Direct Dimensions will be presenting our ShapeShot concept in the 60 second pitch format, as well as taking ShapeShots (a 3D snapshot) of the attendees. Make sure to stop by our booth and say hello.

Vote for Direct Dimensions as The Hottest Tech in Town

2010-09-10T09:48:00.001-05:00

GBTC (The Greater Baltimore Technology Council) is holding a "Hottest Tech in Town" competition as part of their 21st annual TechNite event. Direct Dimensions, showcasing our ShapeShotTM service, is one of the finalists and we would appreciate it if you took the time to vote for us!

Click here to read more about ShapeShot!

Click here to vote for Direct Dimensions as the Hottest Tech in Baltimore!

Everything You Always Wanted to Know . . . Model Formats

2010-09-09T11:24:00.002-05:00

Chapter 7: Digital Model Formats - The Many Flavors of 3D CAD

We’re going to take a little pause in our Everything You Always Wanted to Know About 3D discussion. We’ve talked about the many things you can do with a CAD model but that can lead to some questions. How can I use an OBJ file and how is it different from an STL? Can an IGES and a STEP file essentially be used for the same thing?

These are what we call the “Flavors” of CAD and we’re here to provide you with a short list to help clear up some details.

The Various CAD Flavors:

* ASCII (or ASC) – an X,Y,Z point cloud file in ascii text format.
* DWG - This is a native AutoCad drawing file
* DXF – “Drawing Interchange File” - a neutral version of a DWG file
* IGES – “Initial Graphics Exchange Specification” - a neutral format for exchanging CAD data between many different software programs
* OBJ – an open data format that represents the vertices of polygons
* PRT – a native CAD format for Pro/ENGINEER and NX (Unigraphics)
* SLDPRT – a native CAD format for SolidWorks
* STEP – "Standard for the Exchange of Product model data," (ISO 10303) an advanced neutral format for exchanging CAD data between many different software programs.
* STL – “Standard Tessellation Language” - a polygonal model format similar to OBJ and several others
* WRL (VRML) – “Virtual Reality Modeling Language,” a polygonal file similar to OBJ, STL and several others and can include color
* X_T - a semi-neutral CAD format

Wikipedia also maintains an extensive list of CAD file formats that might be of further interest.

Neutral Formats:

From the list above you’ll notice that some CAD formats are considered neutral, specifically IGES and STEP formats. These two formats were specifically created to neutrally exchange 3D CAD data across different CAD packages.

IGES was created in 1979 by a group of users (including Boeing and GE) with support from the Department of Defense (DoD) and NIST to exchange data more easily. Since the late 80’s the DoD has required that all Digital Project Manufacturing Data (PMI) be deliverable in IGES format.

STEP is an ISO standard released in 1994 to be the “successor” to IGES. While widely used it has never totally replaced the IGES format.

Extra Flavors:

While the above examples are standard across CAD packages, many industries, such as Architecture and 3D modeling for computer graphics have their own packages and files types. We like to think of these as extra flavors, like CAD dessert.

3D Graphics – 3D graphics formats are generally proprietary according to package. Some popular graphics programs are, 3D Studio Max, Maya and Lightwave. Popular gaming companies such as Blizzard Entertainment and other film studios often develop their own in-house formats. However, many consumer 3D graphics packages can import OBJ files.

3D Modeling for Architecture – A new style of modeling for facilities, such as buildings and processing plants, is developing rapidly. This new CAD software contains a relational database component to store metadata for the design entities, such as the style and make of windows or doors, or the schedule of the I-beams and piping. This new class of software is termed BIM for Building Information Modeling and is working to combine facilities management into the database concept as well.

The above list is just a small taste when it comes to the variations of CAD, but they are the most common files used. If you have any questions you should just ask your 3D service provider and they will be happy to help. You can always ask us questions at info@dirdim.com.

The next post in this on-going series will feature a more in-depth discussion and examples of using 3D data for various types of visualization. Stay tuned!

Case Study: The Awakening

2010-09-04T07:44:00.012-05:00

3D Laser Scanning and Digital Modeling Allow Precise Repositioning

“The Awakening” is a 70-foot tall sculpture by J. Seward Johnson, which depicts a man struggling to free himself from the Earth. The installation, which had been a landmark for nearly three decades in DC’s Hains Point, is comprised of five aluminum body parts: a right foot, a left knee, a right arm, a left hand, and a bearded face. It was originally installed in 1980 and became a well recognized attraction next to the Potomac. It had been on loan to the U.S. Park Service by the artist.

But by 2007, the piece was sold to a developer and it became necessary for the sculpture to be moved.

Moving the sculpture and re-installing it in its intended orientation proved to be a true logistical and spatial challenge. Jon Lash, CEO of Digital Atelier, called upon Direct Dimensions to find an affordable and accurate solution to document “The Awakening” in its exact current state and provide him with a 3D plot showing the intersections of the mating surface of the sculpture with the ground. The plots would then be used to prepare the new site to receive the sculpture in its original configuration.

In November, 2007, 52 scans of the sculpture were taken on-site in Hains Point, both with the Konica Minolta Vivid 9i camera, and with the Trimble FX scanner. A spherical scanner like the Trimble FX captures everything in its line of sight, radiating outward from the scanner’s origin.

In the scanning process, the sculpture was approached as five individual pieces, with the scanner capturing each individual piece in its entirety, as well as some of the surrounding pieces. This setup allowed the Direct Dimensions team to reassemble all the pieces together in a single coordinated model, using PolyWorks software. Each scan was scrubbed to pinpoint only the data set required, then properly aligned and polygonized into an integral model.

The final deliverables to Digital Atelier were complete 2D and 3D plots, which showed the entire sculpture aligned into a single coordinate system. These plots allowed the project’s engineers to prepare the new site for the sculpture’s relocation, which occurred on February 19th, 2008.

“The Awakening” now rests in its intended orientation at National Harbor, on the Eastern Bank of the Potomac River.

3D Scanning Downstream Applications: Visualization and Industry Specific Uses for 3D data

2010-08-27T15:51:00.004-05:00

We wrap up this month's discussion of downstream applications with examples of visualization and industry specific uses of data.

Visualization/Animation

This application definitely falls into the realm of advertising and entertainment but also museum presentations, legal cases, and even high quality training simulations are also all great uses for 3D model visualizations and animations.

* Direct 3Dview of your object – can be used to create an on-line 3D catalog or proof of concept.
* FaceScan – scanning a person for animations, avatars, mass personalization of consumer products, or even simulation programs.
* Animation – recent scans of people, objects, and structures have been used to create commercials, films, music videos, and video games.
* Rendering – high quality 2D renderings using 3D models can be used for marketing purposes. Renderings of structures and viewpoints have also been used in legal cases to prove/disprove eyewitness accounts.

This animation is a great example of scan data used for a visualization:

Industry-specific Applications

While many types of industries can utilize the previously listed applications, there are a few 3D model apps that are very specific, but we feel we should list:

* Architecture/Construction: scanning facilities for BIM databases and creating traditional blueprint drawings

* Museum Research/Fine Art: investigative scanning for provenance and comparative research

* Virtual 3D Worlds: 3D scanning facilities, objects, and people specifically for use in virtual worlds and social networks, such as Second Life

Same 3D Data, Many Different Uses: Repurpose!

Often, with just a little bit of extra work, you can create different, valuable deliverables with the same basic scan data or 3D model. Some examples are:

* A consumer products company has an object scanned so that it can be prototyped. What they might not know is that with a little tweaking of the model they can also gather the measurements needed to create perfectly fitting packaging and also creating photorealistic models for subsequent advertising or a virtual catalogue.
* An aerospace company has a cockpit scanned for human factors analysis. If enough data was initially collected, that same data could be used to help create training simulations.
* A major museum has a sculpture in its collection that is rapidly deteriorating and they want to scan it for documentation. That data could be used to create high quality mini replications to be sold in the gift shop or for research (possibly comparing it to similar castings by the same artist).

The Sky is the Limit!

The above examples are just a drop in the bucket when it comes to uses for 3D models. If you have a possible application that you think a 3D model would work for, you should just ask your 3D service provider if it can or has been done. If they are anything like us, they will either have already done it (or tried it) or be so intrigued by your application that they are willing to give it a shot! And if you can’t do it yet, check back often; new applications and methods are being invented every day.

The world of 3D imaging, modeling, and engineering continues to grow at such an incredible rate that older applications are always being improved upon and new ones are always being dreamed up.

If you have any questions, feel free to contact us!

Rapid 2010 Video Overview

2010-08-26T15:56:00.005-05:00

If you didn't get a chance to visit the Rapid 2010 show in Reno you can watch a quick video overview below.

Look for Direct Dimensions taking 3D ShapeShots around the one minute mark!

3D Scanning Downstream Applications: Inspection and Replication

2010-08-24T20:39:00.006-05:00

Inspection/Analysis

While we also covered this as a type of process, inspections are a great use for 3D data, particularly for any types of manufacturing. Using our advanced laser scanning and reverse engineering tools and processes, Direct Dimensions can inspect and analyze your part or object in a variety of ways:

* Compare a scanned part/object to a "nominal" or intended design model
* Compare a scanned part/object to 2D drawing dimensions
* Compare a scanned part/object to another scanned part/object

Replication/Reproduction

While this will be covered in depth at a later time, Replication is one of the earliest and still most important uses for a 3D file. Using either 3D printing or milling processes, your digital file can be created as a physical part. After you have laser scanned or reverse engineered your part, there are virtually limitless options for replicating that object. Replication can be used for:

* Scaling in either direction
* Restoration
* Manufacturing Prototypes
* Making Products

Everything You Always Wanted to Know About 3D Scanning: Downstream Applications

2010-08-13T13:16:00.003-05:00

Re-Engineering/Design

Yesterday we began discussing downstream applications for digital models. Today's downstream application is Reverse Engineering.

While Reverse Engineering as a process was covered in Chapter 4, it is also an application that is particularly useful in the Aerospace/Defense and Industrial Design industries. With a Reverse Engineered model you can make engineering and design changes of your part or object in a variety of ways or use it for specific types of analysis:

* Add or subtract design features to the existing part or object
* Use as a base model to design a new part or object
* Use model for FEA and similar analyses

A good example of this is an aging aircraft job that we worked on. For this job we laser scanned the existing pressure seals on the rear cargo door of several c-2 aircraft. The scan data was analyzed to re-design the seals based on the actual "as-is" door conditions. This process provided for accurate manufacturing and installation of the new seals. You can read more about this particular project on our website.

You can see an example of scanning an aircraft for FEA analysis below:

Everything You Always Wanted to Know About 3D Scanning : Downstream Applications

2010-08-12T13:33:00.004-05:00

Chapter 6: Downstream Applications for 3D Data

In our on-going series about 3D scanning, we’ve reached the fun part! What can you do with a 3D model? Practically anything!

In a world that is increasingly digital, most industries now utilize 3D files in some fashion. We’re seeing them show up in many different places lately.

At this point in the process (having read sections 1-5), you have your 3D model from your scanned original part. It has been either digitally modeled into a polygon format or reverse engineered into a CAD format, according to your needs. But, you can do so many things with your 3D data – things you might not have even thought of yet!

Section Six covers the different downstream applications for 3D data files and because there are so many different applications to talk about, we are going to break out the info into multiple posts.

Downstream applications generally fall into the followings categories:

* Documentation/Archival
* Re-Engineering/Design
* Inspection/Analysis
* Replication/Reproduction
* Visualization/Animation
* Various Industry-specific Applications

Documentation/Archival

After your part or object has been laser scanned and modeled you now have a digital "backup" of the object. Scan data for archival purposes is useful for a number of industries: Aerospace/Defense, Consumer Products/Industrial Design, Architecture/Historic preservation and Museum/Fine Art. At Direct Dimensions we’ve scanned many objects specifically for the purpose of creating a digital document. Archival scans have ranged from the Lincoln Memorial (post-9/11) to a huge rare meteorite to legacy aircraft parts that are no longer made.

This digital model will:

* Protect you from accidental part loss, almost like an insurance policy
* Provide you with a working "virtual" blueprint in order to rebuild, recreate, or remanufacture
* Give you the ability to start from a base model and create something new without having to start from scratch

A good example of something scanned for documentation purposes is the Lincoln Memorial.

You can read more about the Lincoln Memorial scan here or watch this animated fly-through we created using 3D laser scan data.

Check back soon because we'll be talking about more downstream applications including reverse engineering and inspection.

Case Study: Biodiesel University Mobile Lab

2010-07-30T08:19:00.011-05:00

Promoting Energy Education in a Mobile Laboratory

Direct Dimensions traveled to a bus maintenance yard near Washington, DC to 3D laser scan a decommissioned city transit bus formerly owned by the Washington Metropolitan Area Transit Authority. The scan was performed for the Biodiesel University, a non-profit organization based in Olney, MD which seeks to educate students, teachers, and the public at large about renewable energy and environmental stewardship.

Dan Goodman, executive director of Biodiesel University, called upon Direct Dimensions to aid in converting the donated WMATA bus into a mobile educational lab, which Goodman has described as “part classroom, part hands-on science center, and part theme park ride.” The engineering challenge required cutting-edge capabilities from Direct Dimensions to not only scan the bus but also to create an accurate 3D CAD model so the bus can be repurposed for its educational mission. Given the current energy situation and attention to renewable energy, the project was captured on video for a featured story on ABC News.

To start the project, Direct Dimensions industrial designer Glenn Woodburn used the FARO LS long-range 3D scanner to take six scans of the bus’s interior and exterior in less than two hours. Each scan collected over 25 million 3D points providing a very high-resolution ‘point cloud.’

This captured raw data was then provided to Direct Dimensions designer Dan Haga, who created an accurate and detailed 3D CAD model reflecting the actual existing geometry of the bus.

Then using concept sketches and design input provided by Biodiesel University, Haga continued to layout and design the educational lab including the placement of the operational equipment that will eventually be installed in the bus when it is converted for its educational purpose

The final work, delivered in digital format to Biodiesel University, included several photorealistic graphical renderings and a 60-second animated 3D virtual tour of the overall mobile lab design.

By showcasing these materials digitally through its website and email, Biodiesel University can generate additional support for its program and mission. “The renderings and virtual tours present the concept for our mission in a very compelling manner. We’re grateful for the effort and enthusiasm that Direct Dimensions has shown for our project,” states Dan Goodman.

Betascape Recap

2010-07-21T08:13:00.005-05:00

Thanks to everyone who braved the heat and took the time to come see us at Betascape. It was an amazing event and we are already looking forward to next year.

We took over 600 ShapeShots (3D snapshots) of Betascape attendees, including Governor O'Malley.

If you didn't get the chance to come out and have your ShapeShot taken, you can see ShapeShot in action in this news story about Betascape:

A special thanks to Heather Sarkissian and her team for their hard work organizing the whole event.

ShapeShot at Betascape

2010-07-15T08:50:00.001-05:00

Going to Artscape this weekend? Intrigued by the idea of seeing yourself, your kids or even your dog in 3D?

Then make sure to stop by our ShapeShot booth in the Betascape tent and have your ShapeShot (a 3D snapshot) taken.

Betascape, being held in conjunction with the Artscape festival, will showcase innovative and interactive technology from companies all based in the Baltimore area. Activities for the whole family will include powertool drag racing, a robot exhibit, an arcade and video game hall, and the opportunity to get a 3D ShapeShot of your face!

ShapeShot will be at Betascape July 16-18. The Betascape tent is located outside of the MICA Brown Center.

Everything You Always Wanted to Know About 3D Scanning Part 5

2010-07-13T11:26:00.001-05:00

Chapter 5: Inspection/Analysis - Comparison to CAD

We are almost ready to move on to downstream applications for 3D models, but before we jump into that, we need to talk about one more application for scan data. Chapter Five will cover how this data can be utilized for quality inspection.

Important Terminology

CMM - Coordinate Measuring Machine, a mechanical device that obtains 3D coordinates by probing, may be either touch probe based or non-contact, portable or stationary, or motorized or manual.

Laser Tracker - sends a laser beam to locate a reflective target held against the object to be measured. The beam reflects back to the tracker and calculates the distance and angle of the targets location. Laser trackers are a great option when you need extreme accuracy over larger measurement ranges.

Color Map - a graphical display for visualizing dimensional differences between the measured shape of an object and its nominal CAD model; deviations are mapped to a color spectrum indicating location and magnitude. A reference key maps the deviations to values.

A History Lesson

While we think of the 3D scanning industry as something very new, the first 3D digitizers, Coordinate Measuring Machines (CMMs), were actually built in the 1960’s and the entire purpose of this development was to perform dimensional inspections. Fifty years later, inspections are still one of the most common uses for 3D digitizing and scanning systems.

In the late 1980s engineers at the then-Martin Marietta (including Direct Dimensions’ founder and president Michael Raphael) became aware of a company making articulating arms for medical measurements and they began working with the company (Faro Technologies) to develop a portable CMM for inspections in the aerospace industry. After the creation of the portable CMM, the options for 3D measurement and inspection exploded. Laser Scanners were added to the portable arms and then Laser Trackers were developed.

Twenty-five years later, portable scan arms are common measurement solution in major manufacturing firms across the world and in industries ranging from aerospace to automotive and power generation to medical.
Types of Inspections

There are many different types of inspections that can be done utilizing 3D technologies:

* One of the fastest and most informative types of inspections is the Dimensional Deviation, CAD to Part Inspection. A typical process for a Scan Arm, the scan data is compared to the original CAD model in a software package which will then show deviations by a color map.
* A variation of the Dimensional Deviation is the Virtual Assembly Analysis. By using reference points, such as interface datums, we have the capability to, in a virtual environment, simulate and identify how parts will fit together in their real-world assembly. We can do this by using assembly characteristics of the part (such as weld points, slots, and holes) to apply the mating constraints during assembly. This is also known as a “reference point fit” which can discreetly control part movement in any axis of each control point. The analysis can show part collision or spacing in a real world scenario done virtual.
* Parts can also be measured while they are in the process of being machined, an On-Machine Inspection allows for important characteristics to be measured and changes to be made while the piece or tool is still being created. These are typically done with either a Portable CMM with probe and scanner, or a laser tracker depending on the size of the object being machined.
* Similar to on-machine inspections, are real time inspections for Installation Alignment. This is helpful for installations of major equipment and is typically done with a laser tracker, PCMM, or similar.
* Perhaps the most comprehensive of the inspections is the First Article Inspection (FAI) which involves a thorough point to point inspection of a physical part against the production drawing dimensions. This is a very typical process for a portable CMM.

Getting Started

In the previous chapters, to get you going, we discussed the software products that we use literally every day here at Direct Dimensions. Below are the products that take the 3D measured data from the portable arms and scanners and perform the inspection analysis processes.

Each of them has some capabilities to perform the two main types of inspection – discreet point dimensional inspection and dense point cloud comparison analysis. Some have more comprehensive capabilities that include GD&T or special case analyses; and some specialize in certain areas such as ease of use or multi-scanner integration more than others.

At Direct Dimensions, we use all of these regularly and help our customer understand the strengths of each package relative to their specific application and company needs. If we are performing the project for someone as a service, they get the satisfaction of knowing we will use the best software for their inspection. Feel free to call us directly for more specifics on how these packages compare for your needs.

* CAM 2 Measure X (by Faro)
* Geomagic Qualify
* InnovMetric PolyWorks Inspector
* Rapidform XOV
* Verisurf

Now what can I do with my model?

Having learned what you can do with your data: inspect, reverse engineer or digitally model, we are now ready for the fun part! Chapter 6 will be an overview of the downstream applications for 3D models. The possibilities are numerous and we and our customers are thinking of new ideas every day.

CMSC 2010

2010-07-12T14:24:00.000-05:00

If you are at CMSC this week, make sure to stop by booth 107 and say hello!

3D Scanning Newsletter - July

2010-07-08T11:16:00.004-05:00

July's newsletter includes the following highlights:

15 Great Projects Over the Past 15 Years:
In honor of our 15th anniversary this year, we picked out some of our favorite and most impressive projects. It wasn't easy to choose just 15 but we managed to pick out one incredible project per year.

Recreating the First Flight:
For this story we looked back at one of our first major jobs - digitize and replicate the original 1903 Wright Brothers' Propeller for the 100th Anniversary of Flight.

15th Anniversary Slideshow:
See the projects, people and events that have contributed to an amazing 15 years.

A Note from Michael Raphael

2010-06-30T09:00:00.001-05:00

Direct Dimensions, Inc. began offering portable 3D measurement services in the spring of 1995. At that time, 3D industrial measurement technology was in its infancy as portable computing power was just beginning to develop. Somewhere around then we got our first laptop – hardly even a computer much less a laptop by today’s standards!

Having helped develop a revolutionary new industrial 3D measurement device called the Faro Arm in the early 90’s, I was inspired to start this company dedicated to the application of advanced 3D measurement technologies for a wide variety of uses. More than a company, we strove to create an environment which inspired innovation and development; a place where our employees, as well as our customers and vendors would embrace the challenge of implementing new technologies.

Year after year, together, we have pushed the limits of a broadening range of 3D technologies to solve increasingly complex problems for an expanding spectrum of industries and applications. Today we can look back at our portfolio of thousands of such projects – all contributing to a body of knowledge within our company that I feel is unsurpassed anywhere in the world.

Fifteen years ago we started with a single Faro Arm. Shortly after that we added a Kreon laser line scanner. Since then we have continued to add new tools for solving 3D problems of nearly every size and shape. Our company has essentially evolved into a working R&D lab, outfitted with advanced equipment and talented employees all underwritten by the services and products we provide to our customers.

As we continue to take on new challenges, new employees, and new equipment, we will continue to discover better ways to solve 3D problems. Projects that were unimaginable 15 years ago and nearly impossible 10 years ago, we can now accomplish in hours. Our innovation and perseverance have allowed us to expand our customer base beyond our original aerospace roots. We now provide fast, affordable, and accurate 3D scanning and modeling services to virtually all industries, including art, architecture, consumer products, the medical field, and the entertainment industry.

Beyond our little 3D industry, recent innovations in social media now allow us to keep in better contact with our admirers. The creation of YouTube and SlideShare offer excellent platforms to showcase our highly visual projects and presentations. We also send out regular newsletters, have a company blog, and we even tweet!

A special thank you to our many wonderful customers, vendors, and employees who have helped make the last 15 years so successful. We look forward to the next 15!

Michael Raphael,
Founder, President & Chief Engineer, Direct Dimensions, Inc.

15 Great Projects Over the Past 15 Years

2010-06-30T08:23:00.007-05:00

Over the past 15 years we've worked on many truly incredible projects. From art and architecture to aerospace and automotive, and these are just the A's. Below are 15 of our favorites, one from each year, and it wasn't easy to choose.

1995: Olympic Sculpture Brought to Life - One of our first 3D sculpture projects way back in our founding year, was to digitize a 4-foot model of a sculpture to help fabricate a monumental sized public art piece for the 1996 Olympics Games in Atlanta. Our 3D data was used for structural analysis.

1996: Power Generation Components - We reverse engineered our first compressor, impeller, turbine blade, and diaphragm way back in 1996 for upgrading power plants. Back then we used contact digitizers before the laser scanners of today existed.

1997: Recreating Unique Automobiles – One of our earliest historic automotive projects was digitizing a one-of-a-kind 1951 Cunningham roadster, considered the first modern American sports car. Our data was used to create reproductions.

1998: Digitizing the Wright Propellers - To recreate the Wright Bro.’s first flight from 1903 in honor of the 2003 centennial, an airplane reproduction company asked us to reverse engineer original propellers from several historic Wright planes. We collaborated with the US Army in Edgewood.

1999: 3D Digital Facial Prosthetics – Back in 1999 we scanned our first ear to make a medical prosthesis. We scanned a plaster cast of an ear and mirrored it to create a digital version of the missing opposite ear. This digital file was also used to make an RP for a surgical guide.

2000: Aircraft OML Scanning for Analysis – Early in the new decade we scanned our first of many "outside mold line" aircraft exteriors for CFD analysis. Back then we used a laser tracker, today we use the amazing Surphaser.

2001: Lincoln Memorial Scan - Just weeks after 9/11, the U.S. Gov't called with a very special request. They wanted to see how 3D scanning could digitally preserve monuments and artifacts in case of catastrophe. We demonstrated this with Abe at the Lincoln Memorial.

2002: Monumental Church 'Monument' - We traveled to Richmond, VA to 3D laser scan a decaying marble monument from 1811. Our completely restored digital model enabled the rebuilding of a new monument exactly as it was designed originally.

2003: Ray Lewis Marble Bust – We scanned Baltimore Raven's player Ray Lewis and made a beautiful life-like marble bust which was auctioned off for his charity. Since then we've done Amelia, Kelly Ripa, and Natalie Portman. Oh boy!

2004: Tomb of the Unknown Soldier – We laser scanned and digitally restored the Tomb of the Unknowns. Our 3D digital model may be used one day to fabricate a replacement for the cracked monument.

2005: Scanning the Liberty Bell - One of our most significant efforts ever has been our work with the Liberty Bell. We have scanned it three times over 6 years with increasingly better technology. Today we have a fingerprint level digital model of this famous icon.

2006: 3D Animated Political Cartoons – We have a lot of fun working with renowned political cartoonist - Kal. We scanned his exaggerated clay sculptures, including George W. Bush, Hillary Clinton and Barack Obama so he could make 3D animated political cartoons.

2007: 3D Scanning Helps U.S. Solider – For years we've worked with Johns Hopkins to develop radical new methods for 3D digital prosthetics. In 2007 we helped create a new nose for a soldier wounded in Iraq. This was truly one of our most rewarding projects and it was later featured on CNN.

2008: Laser Scanning Buildings for BIM – As early adopters of long range scanning for historic preservation as well as ships and airplanes, its logical to also scan and model large building structures. Often these models feed into BIM for downstream re-design and analysis.

2009: Scanning Aircraft with the Surphaser – We are constantly testing new 3D products from all over the world. This year we implemented the Surphaser as a fantastic new scanning tool for a wide range of projects - from cars to airplanes and everything in between!

2010: Matisse Sculpture 3D Analysis - A major art exhibition opened at MoMA in New York featuring extensive technical analysis of Matisse's "Back" sculptures. Our team played a huge role with our various 3D technologies for scanning, modeling, and analyzing the pieces for this important and unique exhibit.

Our team at Direct Dimensions, combined with our tools, history, experience, and skills, is quite unique in the United States and perhaps the entire world. We simply don't know of another organization with the variety of tools and talent that we've accumulated over the past 15 years. The above glimpse into 15 projects over our first 15 years amazes us and should amaze you too. It is very exciting to look back but even more exciting to think about what the next 15 years will bring.

Thanks for reading thru this and we welcome your feedback and reposts to your friends about this amazing list.

From your 3D friends at Direct Dimensions.

Case Study: Engine Block Modeling

2010-06-24T12:20:00.006-05:00

Scanning and Modeling Helps Customer Meet Tight Deadline

A few years ago Direct Dimensions was approached by Patrick Power Products, Inc. (P3I) with a typical 3D problem: they needed an engine modeled into a 3D digital format. P3I is a cutting-edge company specializing in the development of auxiliary power generation systems. This particular project was for the U.S. Army, which had contracted P3I to use their patented technology and process to convert a rotary engine to run on diesel fuel.

The engineers at P3I needed a complete native CAD model of the rotary engine with full parametric history that would allow them to bring it into SolidWorks computer-aided design (CAD) software so they could design the rotor housing and spark plug area to fit their patented “pre-chamber”. The problem was that the contract had a very fast turn around and, while the engineers at Patrick Power certainly had the skills necessary to draw the engine in their CAD package, they were short on time.

Given this challenge, Patrick Power Products contracted Direct Dimensions to rapidly laser scan and model the engine components. With the file of the existing engine provided by DDI, the engineers at P3I would have ample time to redesign and test their technology before their deadline.

Over the next several days, Direct Dimensions technicians digitized and laser scanned two engines using a portable FARO Scan Arm system. The first engine was scanned in its entirety and the other was disassembled to scan specific areas in more detail. such as the rotor housing. The FARO system provides users both a contact probe for high accuracy geometric features and a non-contact laser scanner for complex contoured cast surfaces.

With the raw 3D data gathered during scanning, the DDI engineers then created accurate 3D CAD models of the engine with specific attention paid to the rotor housing and mounting points. These models allowed Patrick Power Products to design and manufacture their prototype.

The prototype ran successfully on the first test and P3I completed their contract ahead of their deadline. According to Mike Griffith, an engineer at P3I, "with a short duration contract, if we had not had that model, we never would have gotten the engine running. We could have still been making drawings but we actually ended up ahead of schedule."

Everything You Always Wanted to Know About 3D Scanning Part 4

2010-06-18T15:24:00.002-05:00

Chapter 4: Reverse Engineering
Converting Raw Point Clouds into CAD Formats: Step 2 – Files that can be brought into Parametric Modelers

You’ve read our overviews, figured out how to collect data, and now that you have this data, what do you do with it? Chapters Three through Five will cover how this data can be processed into more usable digital forms.

In Chapter 3 we discussed processing 3D data into polygonal models and dumb solids, but what happens when you need more than a simple mesh file or you must have geometry features to enable your redesign process? As previously discussed, we categorize the processing of the collected data into two main categories: Digital Modeling and Reverse Engineering. In Chapter 3 we discussed Digital Modeling (polygonal or rapid NURBS dumb solids), but when you need to go beyond these simpler model formats, we call that Reverse Engineering with “design intent.”

Terminology:

Reverse Engineering - the process of measuring and then creating a CAD model of an object that reflects how the object was originally designed (with its design intent).

Design Intent - the intended design of an as-built physical object. Every manufactured part or object varies from its original intended design by some factor. These imperfections can be identified, analyzed, and corrected during the reverse engineering process.

As-built - modeling which captures the exact physical shape of an object as it actually is, with its imperfections (as opposed to its design intent).

When should I request a Parametric Model vs. the simpler Rapid NURBS or Polygonal Mesh Model?

So when does a project fall into the category of Reverse Engineering as opposed to Digital Modeling? Why should I opt for Reverse Engineering when it sounds more time consuming and requires additional processing, and therefore is probably more expensive?

At Direct Dimensions our recommendation generally depends on several factors including: shape (organic vs. geometric) and desired file output. If you want to make a Rapid Prototype of a hand-carved chair seat then going the digital modeling route is probably a fine option for you. If you want to scan an airplane to create an accurate model for CFD analysis, need a model of an impeller for flow analysis, or require a model of an engine casing for a redesign then you’ll probably want to spend the time and effort required creating a fully reversed engineered model.

Perhaps the biggest difference between Digital Modeling and Reverse Engineering is the desired file output. People that choose Digital Modeling generally will use the file for Rapid Prototyping or visualization purposes. When you need more than that, either for redesign purposes or for importing models into analysis programs, you generally choose to Reverse Engineer, which means bringing your files into parametric modeling software. There are essentially four types of models that work for this (two of them we discussed in the previous chapter):

* A Rapid NURBS ‘dumb solid’ (previously discussed in Chapter 3) starts with the polygonal model. NURBS surfaces are wrapped over the polygonal mesh. This wrapped surface model is smoother than a polygonal model and generally contains no regular geometric features. This type of NURBS model can be brought into parametric modelers such as SolidWorks (albeit with no parametric history – which is why we call it dumb).
* The bridge between Digital Modeling and Reverse Engineering is the Hybrid Model (previously discussed in Chapter 3). A hybrid model is a polygonal model that has been converted in a rapid NURBS surface model and then also uses some traditional solid modeling techniques. It is commonly used when basic geometric features, such as holes & edges, blend with complex organic contours, such as a machined casting.
* The Hybrid ‘dumb solid’ model is considered a step up from the fully Rapid NURBS, in both time and effort, but certainly not as time consuming as a fully reverse engineered parametric model. Unlike the Rapid NURBS, which is essentially a wrap around a polygonal frame, the hybrid dumb solid contains some geometric features such as holes, planes, and radii but these features still have no parametric history.
* A fully reverse engineered Parametric Model will have a fully functioning feature tree, allowing for complete redesign if necessary. These models are built as if they were engineered from scratch, making them perfect for the reverse engineering of legacy parts and redesigns.

Design Intent or As-Built?

When choosing to reverse engineer a part, it is important to decide if the part should be reverse engineered as-built (or as-scanned, in its current state) or engineered with its design intent. Often the actual physical production parts are off just fractions of millimeters or sometimes the parts have worn down a bit from the original fabrication. It is important to clarify the end use of the data when discussing your project with a reverse engineering firm so they know whether you need design intent or as-built models.

The Reverse Engineering Advantage

There can be a fine line between Digital Modeling and Reverse Engineering and sometimes both methods can be a valid solution to 3D problems. Some advantages of Reverse Engineering are:

* Can be brought into Parametric Modeling Packages (solid modeling CAD software)
* Parametric Models will have a feature tree that is editable
* Other than Rapid NURBS dumb solids, reverse engineered models contain geometric features such as planes and radii making the models a better fit for designing and measuring.
* Reverse engineered models are great for analysis software such as for CFD and FEA.

Getting Started

In the previous chapters, to get you going, we discussed the software products that we use literally every day here at Direct Dimensions (shown in alphabetical order):

* Geomagic
* Imageware
* Innovmetric PolyWorks
* Rapidform

The CAD packages we use frequently include: AutoCAD, CATIA, Siemens NX, ProEngineer, Rhino3D, and SolidWorks.

What else can I do with a model?

Now that you know a bit more about what we call Digital Modeling and Reverse Engineering you may feel like you don’t need to know anything else about the uses and creation of 3D models. However, there is one more major use of 3D scanning that we want to talk about. The next chapter will discuss utilizing 3D Scanning for Inspection / Analysis.

Everthing You Always Wanted to Know About 3D Scanning Part 3

2010-06-03T14:33:00.002-05:00

Chapter 3: Digital Modeling
Converting Raw Point Clouds into CAD Formats

You’ve read your overview, figured out how to collect data, and now that you have this data, what do you do with it? Chapters Three through Five will cover how this data can be processed.

As you learned in Chapter Two, Direct Dimensions breaks data collection into two common methods: Laser Scanning and Digitizing. We also categorize the processing of the collected data into two main categories: Digital Modeling and Reverse Engineering. In this chapter, we’ll tell you what you need to know about Digital Modeling.

Digital Modeling: the process of creating a computer model of an object that exactly replicates the form of the object. Laser scanners are used to capture the 3D data of the object, and this data is transferred to the computer where it is aligned, edited and finalized as a complete 3D model.

Polygonal Models and Dumb Solids

So, when does something fall into the category of Digital Modeling as opposed to Reverse Engineering? At DDI it generally depends on a couple of factors: shape (organic vs. geometric) and desired file output. As a general rule of thumb, organic shapes tend to fall into the Digital Modeling category, as do polygonal models (STL Files) and Rapid NURBS Dumb Solids.

A Polygonal Model is a faceted (or tessellated) model consisting of many triangles. Facets are formed by connecting points within the point cloud. STL files can be used for visualization, rapid prototyping, design, milling, and analysis software.

A Rapid NURBS ‘Dumb’ Solid (usually in IGS format) starts with the polygonal model. NURBS surfaces are wrapped over the polygonal wire frame. This wrapped surface model is smoother than a polygonal model. The NURBS model can be brought into parametric modelers such as SolidWorks (albeit with no parametric history – which is why we call it dumb).

The bridge between Digital Modeling and Reverse Engineering is the Hybrid Model. A Hybrid model is a polygonal model that has been converted in a rapid NURBS surface model and then also uses traditional solid modeling techniques. It is commonly used when basic geometric features, such as holes & edges, blend with complex organic contours, such as a machined casting.
Do Reverse Engineering and Digital Modeling ever Overlap?

In addition to Hybrid Models, there are instances when it is appropriate to use both Digital Modeling and Reverse Engineering techniques. For example, when collecting data of a large object (such as a plane) for Reverse Engineering, it is necessary to use a laser scanner to capture the massive amounts of surface data. The data output from a laser scanner is a point cloud, but point clouds cannot be brought into any CAD packages. Before the data can be transferred into CAD it must be digitally modeled into either a polygonal model or a Rapid NURBS dumb solid.

The Digital Modeling Advantage

There can be a fine line between Digital Modeling and Reverse Engineering and sometimes both methods can be a valid solution to 3D problems. Some advantages of Digital Modeling are:

* Digital Modeling generally offers a faster and more cost effective solution.
* It presents a great solution for creating solid models when an object has organic contours.
* Offers excellent dimensional accuracy and can be utilized for comparative analysis.
* While it is true that Rapid NURBS Dumb Solid models do not have parametric history, they can be utilized as a base for design work and Boolean functions are possible.
* Unlike raw point clouds, Digital Models can be visualized in rendering software as a solid object, which is great for seeing the overall shape and contour of the model.

Getting Started

In Chapter Two we discussed data collection and various brands of scanners and digitizers that we use on a daily basis. Don’t worry! We won’t leave you hanging on what software packages we recommend for digital modeling. We use the following packages every day at DDI (in alphabetical order):

* Geomagic Shape Studio: Polygonal and NURBS modeling and point cloud to CAD comparison. Geomagic can automatically generate an accurate digital model from any physical part.
* PolyWorks Modeler: Polygonal modeling and point cloud to CAD comparison. PolyWorks can process large point clouds over 100 million points and easily integrates with all standard digitizers and articulating arms.
* Rapidform: Third generation point processing software for creating native parametric "design-intent" CAD models directly from scan data. At Direct Dimensions we often use Rapidform in Hybrid Modeling but it also has a great Rapid NURBS function.

Tackling Reverse Engineering

Now that you know a bit more about what we call Digital Modeling and why it can be a great option, you are ready to tackle Reverse Engineering.

Tomb of the Unkowns

2010-06-01T10:11:00.003-05:00

Laser Scanning the Tomb of the Unknowns

In honor of Memorial Day we thought it fitting to make sure our followers know that the Tomb of the Unknown in Arlington, VA was 3D laser scanned for digital preservation.

Here's a link to the story on our website: 3D Scanning the Tomb of the Unknowns

The solid marble Tomb is cracked - severely - and without controversial repairs it will eventually fall apart. This digital documentation is intended to be used to fabricate an exact reproduction for its replacement.

This is not a new project for us but the 3D documentation of the Tomb is part of an on-going debate within the preservation community. While the 3D digital data has been ready to make a new marble Tomb for years, the replacement project has created a discussion about whether to repair or reproduce.

Everthing You Always Wanted to Know About 3D Scanning Part 2

2010-05-21T12:44:00.002-05:00

Chapter 2: Data Collection

Now that you have a basic idea about how 3D scanning and modeling works, let’s really get started. Before you can have a 3D model, you must have 3D data to create that model. Let’s start there…

So, what are the ways that 3D data can be collected?

There are multiple ways to collect 3D data but two of the most common methods (and the two most frequently used by Direct Dimensions) are laser scanning and digitizing.

During laser scanning, a laser line is passed over the surface of an object in order to record three-dimensional information. The surface data is captured by a camera sensor mounted in the laser scanner which records accurate dense 3D points in space, allowing for very accurate data without ever touching the object.

Laser scanners can be broken down further into types such as laser line, patch, and spherical. The FARO ScanArm, the FARO LS, the Surphaser, Konica Minolta Vivid 9i and Range 7 are some examples of laser scanners that we often use at Direct Dimensions.

The second major method is digitizing, which is a contact based form of 3D data collection. This is generally done by touching a probe to various points on the surface of the object to record 3D information. Using a point or ball probe allows the user to collect individual 3D data points of an object in space rather than large swathes of points at a time, like laser scanning. This method of data collection is generally more accurate for defining the geometric form of an object rather than organic freeform shapes. Digitizing is especially useful for industrial reverse engineering applications when precision is the most important factor. Stationary CMM’s (coordinate measurement machine), portable CMM arms, and the FARO Laser Tracker are all examples of digitizers that we often use at Direct Dimensions.

Other methods of collecting 3D data include white light scanning, CT scanning and photo image based systems. These technologies are being utilized more frequently in the field of 3D scanning and new applications are being discovered every day.

To be digitized or laser scanned?

A general “rule” is that scanning is better for organic shapes and digitizing is most accurate for geometric shapes. In general, laser scanning is also used for higher-volume work (larger objects like cars, planes, and buildings). Laser scanning is also a great option for people who need 3D data of an object but would prefer that the object not be touched, such as for documentation of important artifacts.

Digitizing is often used for our engineering projects and first article inspections, in instances where precise measurements are required for geometrically-shaped subjects. This includes objects that have defined lines and planes and curved shapes, like spheres and cylinders.

This doesn’t mean that you can never laser scan a part with many geometric features or that you can’t digitize a plane (an entire plane can be digitized, believe us - we’ve done it!) or even a sculpture. These are just rules of thumb.

Utilizing multiple methods of Data Collection

There are projects when it is more cost and time effective to use multiple methods of data collection. A good example is a cast part with geometric machined features. You might need a 3D model of the entire part but really need incredible accuracy on the machined features while the freeform cast surface itself is not as important. In such a case it can be much more effective to laser scan the entire part and then digitize the geometric features. The data can be combined during the modeling phase (more on that in the following chapters).

Additional Scanning Information

Because you are trying to collect the most accurate data possible, there are a few more things to keep in mind before you run out and start scanning everything in sight.

* Bright light sources in the area, including the sun, can really mess up your scan data. At Direct Dimensions, if we are laser scanning an object outdoors we prefer to do it at night if able. Light can reflect off of your scanning object and create “noisy” data. This brings us to:
* Very reflective materials generally do not scan well. This can be avoided with a light coating of white powder spray (or anything that dulls the reflectivity). There are also some scanner manufacturers who are actively working to solve this problem.
* Fixturing: whether you are laser scanning or digitizing, it important that your scan object will not move while you are collecting data. The tiniest motion will cause inaccurate data.
* If you need hard to reach/impossible to see internal data, you should consider CT scanning or destructive slicing, both can be great ways to augment your data. (more on those later).

Moving on to 3D modeling

Now that you have a good idea of what you need to collect data, you are ready to learn all about the various ways the data can be modeled. Chapters three through five will cover, 3D Modeling, Reverse Engineering, and Inspection Analysis.

Come See Direct Dimensions at Rapid 2010

2010-05-14T12:41:00.006-05:00

Next week we'll be at the Rapid show and 3D Imaging Conference. Stop by booth 206 and say hello. While you are there make sure to get your very own ShapeShot taken!

If you are going to attend the conference portion of the event, don't miss our Director of Art Services, Harry Abramson, give his presentation "3D Imaging for Sculpture Conservation and Research" on the afternoon of the 18th. Harry will discuss some of our more fascinating case studies involving 3D imaging and rapid prototyping for the creation, restoration, replication, and in-depth study of fine sculpture.

See you there!

Case Study: Rosetta Stone

2010-05-13T13:07:00.006-05:00

Ancient Writing Converted to 3D Digital Form

In February of 2008, Joel Freeman of The Freeman Institute Foundation came to Direct Dimensions with an interesting project. Within his collection of historical artifacts, Mr. Freeman owns an original replica of the Rosetta Stone, the famous tablet discovered after Napoleon’s 1798 conquest of Egypt. The tablet bears an inscription of a decree by Ptolemy V circa 196 BC, written in three different languages: two distinct forms of Egyptian hieroglyphics and one form of classical Greek. The Rosetta Stone was so important in the deciphering of some hieroglyphics that the term has come to mean any document or key instrumental in the decryption of a language or code. The original Rosetta Stone has been displayed by the British Museum since 1802, but a handful of first-generation castings were made of the tablet for reproduction.

It was one of these original castings that Mr. Freeman brought to Direct Dimensions. He wants to make scaled reproductions and to help others understand the importance of this famous tablet.

His cast reproduction is full-size, approximately 38-inches tall by 30 inches wide, made from black resin with the critical lettering inscribed on the flat front face. Because it is only a face casting that is two inches deep, this posed another problem, as he wished to make an accurate replica measuring the same 11-inch thick as the original tablet.

After consulting with the engineers at Direct Dimensions about the project and understand how Mr. Freeman intended to actually fabricate the piece, it was decided that only an extremely accurate 3D digital model of this physical piece could work. The 3D data file would be used to drive a computerized industrial milling machine to carve a highly accurate mold. Direct Dimensions would have to use its most accurate and highest resolution scanning tool to capture the piece.

Over the next several days at the DDI lab in Owings Mills, the cast replica was digitized using a non-contact laser line scanner mounted on a motorized precision coordinate measuring machine, or CMM. This unique scanning system had been integrated a few years earlier by the DDI engineers for projects just like this. With the controlled motion of the CMM combined with the scanner from Kreon Technologies, this system can achieve resolutions approaching 25 microns. This translates to 3D point every one-thousands of an inch (0.001”) - a dot per inch resolution sufficient for capturing even fingerprints in 3D.

The resulting massive point cloud file was so detailed that when processed into it a 3D mesh weighed in at over 10 million polygons. A figure, according to project manager Peter Kennedy, “that definitely strained the limit of our already extensive computing power.”

In addition to the precise scan of the tablet’s front face, a model incorporating the tablet’s true thickness had to be created. With standard photographs and other reference materials provided by Freeman, the digital modeling team at Direct Dimensions used a variety of software products, including PolyWorks, Geomagic, and Z Brush, to digitally sculpt the shape and contour of the original tablet’s back side. The back was then combined with the precise data from the front to complete the high accuracy digital model of the real Rosetta Stone.

The final deliverable in polygon format will enable Mr. Freeman and his other collaborators to mill the completed replica molds. He aims to use his replica as a centerpiece in his educational programming, to be housed in an exhibit in the Black History galleries of The Freeman Institute Foundation.

If you are interested in learning more about the Rosetta Stone or owning a full-size, 3D replica, please visit www.rosettastonereplicas.com.

Everthing You Always Wanted to Know About 3D Scanning

2010-05-05T10:49:00.003-05:00

Last year we ran a feature in our monthly newsletter called "Everything You Always Wanted to Know About 3D Scanning *But Were Afraid to Ask." The 10 installment educational series covered different aspects of 3D technologies. We got such positive feedback on the series that we've decided to post an installment on our blog once a week.

Introduction: The Basics
What is a 3D model and how do you get it?

A 3D model is a digital representation of a physical object. If you already have an object, and you want it in a digital form, that’s what we do. Direct Dimensions takes physical objects that you send to us and we use advanced 3D scanning equipment to capture and transform them into 3D digital models.

We do this by processing the raw data gathered during a 3D scan into a digital model that can then be used by you for many purposes. In the next chapter, we'll cover the different methods for collecting this data, including laser scanning and digitizing. A 3D model is incredibly versatile.

Why do I need a 3D model?

3D models can be used for many purposes like making an animation or visualization. They can be used to make design changes to make a new product. They can be used to perform dimensional and comparative analysis of an object, or even FEA and CFD analysis. They can be used for archival purposes - to accurately record the state or form of an object. They can be used to digitally repair damage that has been done to an object which can then reproduce that object in its proper form using rapid prototyping and milling technologies. They can even record your face in intricate detail! (And yes, some of our lasers are eye-safe!). There are no limits as to what can be done once something has been captured in 3D.

In short, our technologies allow almost any physical object to be recreated into a 3D digital format that can be used for just about anything you want.

When? Where? How Large? What are the limitations?

With our various technologies, we can capture objects indoors or outdoors, during the day or at night. The sky is the limit for how large and we also have technology that can capture even the smallest objects. Some of our equipment is portable so we can come to your facility, or you are encouraged to ship your items to our lab.

On the large side, Direct Dimensions has successfully scanned entire airplanes, historic monuments, ships and subs, tracts of land, and large interior spaces like buildings. We’ve scanned mid-size objects like spacesuits, countless consumer products and art work. We've also done tiny, finely-detailed items like coins, medical devices, and dental appliances. We've even captured fingerprints and skin textures! The bottom line is that whatever your object, the tools exist to scan it, and its likely we use them.

What's next?

Now that you know the basics of what can be scanned and how 3D data can be used, you are ready to learn more about the different methods we use for data collection!

Calls for Speakers and Papers

2010-04-15T09:31:00.004-05:00

Two requests to announce:

CMSC announces a call for papers:
The Coordinate Metrology Society (CMS) is sponsoring its twenty-sixth annual conference in Reno, Nevada July 12 -16. The conference brings together measurement system users, developers, manufacturers, and researchers to present and discuss innovative applications, research, and technology developments/techniques of common interest. The CMS Committee is soliciting original papers with this Call for Papers on a broad range of innovative metrology topics.

To read more, click here.

SME Aerospace Measurement, Inspection, and Analysis conference announces a call for speakers:
With a special focus on manufacturing at all levels of the aerospace industry, this event will bring together a blend of technology updates, process optimization ideas, and case studies of others facing similar challenges. The program will consist of two days that can be attended as one whole event or as two single day events.
We invite you to take an active role in this cutting-edge program by sharing your knowledge and experience with current, new and potential users of the technology.
Abstract deadline is May 12, 2010.

Click here for more information.

SME Video "Medical Applications of Rapid Prototyping" featuring Direct Dimensions

2010-04-13T19:43:00.002-05:00

In conjunction with Juan Garcia of Johns Hopkins, we helped the Society of Manufacturing Engineers (SME) produce a video showing the concepts of 3D imaging and rapid prototyping for fabricating custom prosthesis.

Click here to see the video.

The video highlights 3D scanning to help create prostheses and surgical guides, utilizing 3D technologies to aid medical illustration and even creating rapid prototypes with organic compounds such as tissue.

For more information on 3D scanning for custom prosthesis, please visit these other projects:
Hi-Res Prosthetic Hand
3D Scanning Helps Wounded Soldier

Happy Birthday!

2010-04-07T10:51:00.002-05:00

Direct Dimensions, Inc. turns 15 years old today!

ShapeShot featured at GameTech 2010

2010-04-05T09:42:00.007-05:00

Direct Dimensions' "ShapeShot" was featured by Orlando's Channel 13 news on March 29 at the GameTech 2010 military avatar conference.

Click for the news story and video showing the ShapeShot to avatar process.

For more information, also see www.shapeshot.com, or contact us directly.

3D Scanning Newsletter - March

2010-03-31T20:31:00.008-05:00

This month's newsletter includes:

Aircraft OML Reverse Engineering Enables Complex CFD Analysis:
When Texas A&M University Flight Research Lab needed to determine the suitability of a Gulfstream II for a critical flight-test program Direct Dimensions provided them with high quality engineered 3D CAD models that allowed them to perform complex CFD analysis to determine if the aircraft was a good fit.

Williamsburg Coffee House:
Laser scanning captures amazing details from the past during a historic reconstruction project.

Monumental Horse Sculpture:
Digital sculpture enlargement helps fabricate a monumental sculpture based on a clay model.

Direct Dimensions’ 2010 3D Scanning and Modeling Conferences & Events

2010-03-30T12:33:00.005-05:00

Each year Direct Dimensions sends personnel and equipment out into the world to spread the word about our great 3D capabilities at a wide variety of events. We attend many conferences, trade shows, and events over a diverse range of industries from art to medical and aerospace to entertainment. We perform demonstrations, give talks and presentations, and lead technical workshops to help people learn about our latest 3D imaging technologies and how they can use our services and products.

Here are some of the events where you will find us in 2010:

APMM Conference, March 26-28, Boston, MA: Leading a workshop on diverse 3D imaging technologies available to the model making industry at the Association of Professional Model Makers conference.

GameTech 2010 March 29-31, Orlando, FL: Direct Dimensions’ face scanning experts are in Orlando showcasing our ShapeShot concept for this conference that deals with utilizing gaming technologies for military training.

Rapidform SUCCESS Conference 2010, April 20-23, San Francisco, CA: Rapidform’s annual reseller and users meeting, combined with technical training sessions.

RAPID2010 and the 3D Imaging Conference, May 18-20, Anaheim, CA: One of the premiere shows within our industry, RAPID2010 brings the 3D scanning & imaging and additive manufacturing communities together to showcase the newest technologies. Come see us at booth 206!

The American Association of Museums Expo, May 24-27, Los Angeles: We’ll attend the show to meet museum professionals and discuss our depth and capabilities in the areas of digital art and sculpture.

Maryland Society of Surveyors Conference, June 11, St. Michael’s, MD: We’ll be sharing our experiences with BIM (Building Information Modeling) and heritage site scanning.

Coordinate Metrology Systems Conference (CMSC), July 12-16, Reno, NV: This conference provides a professional venue where ideas, concepts, and theory flow freely among participants. The educational atmosphere encourages attendees to network and learn about the latest innovations in the field of portable 3D industrial measurement technologies. Anyone in the metrology field should attend this conference! Direct Dimensions will be at booth 107 and Michael Raphael is a member of the 2010 CMSC Executive Committee.

SIGGRAPH 2010, July 25-29, Los Angeles, CA: This huge conference focuses on digital gaming, entertainment, and animation. Direct Dimensions will again showcase 3D & 4D face capture technologies from Dimensional Imaging.

Aerospace Measurement, Inspection, and Analysis, October 20-21, Orlando, FL: This is a new trade show around the 3rd technical conference from SME to showcase measurement technologies that support aerospace manufacturing. Michael Raphael is again a conference advisor.

International PolyWorks Users Meeting, Oct 26-28, Quebec City, Canada: Gathering of PolyWorks users and resellers, combined with technical presentations and demonstrations hosted by Innovmetric.

Check back often, we’ll be adding more opportunities to learn about 3D scanning!

Case Study: 3D Transforms Idea from Concept to Digital to Manufacturing

2010-03-20T20:46:00.005-05:00

John Jenkins, President and CEO of Jenkz Innovation and Design Group, engaged Direct Dimensions for a unique 3D project. As a Chrysler 300 car owner, he had been interested in purchasing an aftermarket accessory to enhance the vehicle’s front grille. After an exhaustive search, he found that what he wanted did not exist on the market. So being an inventor and entrepreneur, Mr. Jenkins decided to patent and design the accessory himself.

While Mr. Jenkins knew how he wanted his finished product to look, he needed extremely accurate data of the car’s grille area to complete the design. He also needed assistance in getting a prototype created, and eventually engineers who could work closely with his production facility.

After consulting with the staff at Direct Dimensions about the project and understanding how Mr. Jenkins intended to actually fabricate the piece, the engineers opted to use a Faro Arm and Faro Laser Line Scanner to capture the data with an accuracy of +/-0.002”. Mr. Jenkins drove his Chrysler 300 to Direct Dimensions’ lab where it was scanned in just a few hours.

With the precise dimensions and complex contours of the Chrysler 300’s existing grill accurately captured, Mr. Jenkins outlined his concept design for the trim accessory so that it would fit perfectly with the other front trim pieces. Using Rapidform’s unique XOR software for design-intent reverse engineering, a digital model of what would eventually be called the Chrome Mustache™ was created to Mr. Jenkins' specifications.

Once the design team finished the CAD model, this data was transferred to our in-house replication services team to manage the rapid prototype process. Prototypes were then created using stereolithography (SLA), an additive process that uses a laser and liquid resin to layer plastic. A final prototype was then chrome-plated to approximate the anticipated finished product. Although only a prototype, it looked and functioned like a real production part.

Mr. Jenkins then used the prototype, 3D CAD file, and help from the engineers at Direct Dimensions to arrange for the creation of a plastic injection mold. When the production facility had questions or potential problems, the DDI engineers were able to collaborate with them to make minor design changes or answer questions.

The “Chrome Mustache™” is currently available for sale. You can find it at dealerships and distributors across the USA and Canada, or at its website: www.naked300.com

Calling All 3D Artists

2010-03-19T08:35:00.002-05:00

Call for 3D printed art at SME RAPID 2010

Attention artists working with 3D printing technologies, or "additive manufacturing" (AM) - the Society of Manufacturing Engineers (SME) is holding its annual conference, called RAPID, featuring 3D Imaging in Anaheim, Calif. in May 2010.

This years conference will feature a gallery of art produced with AM technologies. A submission entry process is available online with a deadline of March 22, 2010.

Click here for complete information.

3D Scanning Newsletter - February

2010-02-28T22:31:00.007-05:00

Case studies this month include:

3D Scanning Helps USA Luge Improve Aerodynamics - When the USA Luge Team needed 3D models of their sleds for virtual wind tunnel testing, they turned to the team at Direct Dimensions. Using a Konica Minolta Vivid and Faro Arm scanners, DDI not only captured the sleds, but also several athletes to create accurate 3D CAD models for each. Supported with high powered CFD software from the aerospace industry, the US Luge team and their supporters performed complex airflow analysis to minimize drag.

Giant Olympic Sculpture Brought to Life - One of our first 3D projects way back in 1995 was to use the FaroArm to digitize a sculpture model for the 1996 Olympics Games in Atlanta. The 3D data was required for structural analysis. Here’s the classic story about how we first applied an industrial 3D measurement tool to the fabrication of art, something we still do regularly today.

We also highlight the Surphaser HSX Spherical Scanner. If you haven't yet seen this amazing scanner, make sure to check it out. It is the only mid-range scanner on the market; with accuracy great for cars to airplanes!

Click here to read the full newsletter.

If you have not subscribed to our newsletter yet, you can subscribe here.

Direct Dimensions Employee Volunteers in Haiti

2010-02-28T22:31:00.006-05:00

Direct Dimensions Digital Modeler (and amazing volunteer!) Jessica Brodsky recently spent time volunteering with the Relief Foundation in Haiti. Her time was spent distributing medical supplies and working with children at hospitals and an orphanage. She also used her artistic skills to help create a mural in the hospital cafeteria.

We're proud to have Jessie as a member of our Direct Dimensions team!

3D Scanning Newsletter - January

2010-02-01T09:01:00.003-05:00

January's newsletter has been sent out and is also posted on our website.

Articles for January include:

Scanning the Matisses: By special permission, this story presents our work with museum conservators at the Baltimore Museum of Art on the origin of several Matisse sculptures. The story features many of the compelling images we created from our 3D laser analysis of the shape of the sculptures and included in the publication and travelling museum exhibit ”Matisse: Painter as Sculptor.”

Jersey City Reservoir 3 Restoration: Constructed from 1871-1874, Jersey City’s Reservoir Number Three is important both for its historical structures and waterworks as well as for its status as the site of a burgeoning urban eco-system. Direct Dimensions 3D laser scanned and imaged the Reservoir's structures to assist in the restoration process.

CMSC Announces Call for Papers

2010-01-28T15:08:00.004-05:00

CMSC announces a Call for Papers for their 2010 Conference.

Join the ranks of other metrology leaders as a CMSC presenter. Share your expertise with new and experienced users in Reno, Nevada, July 12-16. CMSC is looking for presentations and technical papers that explore technology, theory, and practice that advances coordinate metrology.

As always, Direct Dimensions will be involved in this conference and calling on our contacts to sign up to make presentations. Our company president, Michael Raphael, was elected to CMSC's Executive Committee at last years meeting in Louisville.

Now is the time to submit your abstracts, please see the conference website for more information.

For more details, visit the CMSC website.

Geomagic CEO sitting with First Lady at State of the Union

2010-01-27T13:14:00.005-05:00

Ping Fu, CEO of Geomagic and one of the leaders of the 3D scanning community, has been invited to sit with the First Lady during tonight's State of the Union address.

Earlier this month Ms. Fu was part of a group of CEOs that met with the President and Whitehouse staff as part of the White House Forum on Modernizing Government.

According to an interview with the News & Observer:
"Fu assumes that administration officials wanted someone who represents "game-changing" small or medium companies that created jobs in 2009.

"Somebody was impressed with my company and the things I said" during a CEO technology forum at the White House on Jan. 14, Fu said. "The economy is the main issue, and creating jobs."

Congratulations Ping!

DI4D Open House February 3rd in Los Angeles

2010-01-27T10:12:00.005-05:00

Do you work in the Film or Game industries? Are you in the L.A. area? If so, we encourage you to attend the DI4D Open House. Mimic Studios and Direct Dimensions will be hosting this event to showcase the amazing 4D Video Facial Capture System from Dimensional Imaging!

This revolutionary 4D camera system, based on passive stereophotogrammetry technology from DI3D™, allows you to capture fully-textured 3D facial motion at 60 frames per second! This data can then be output in formats and resolutions for film and game use.

Please call us at 410-998-0880 or email mraphael@dirdim.com for additional information.

3D Scanning Technologies Industry Roundup: “Conversations with leaders in the scanning and digitizing business”

2010-01-13T13:32:00.004-05:00

In our end of the year newsletter we decided to revisit an interview Michael did with 3D Scanning Technologies about the state of the 3D scanning industry. We received some great feedback and thought it might be worthwhile to share it here as well.

1. As a longtime observer in a maturing technology market, what do you see?

MR: The market for 3D scanning is following the usual cycle for other advanced technologies. While some aspects of our field are maturing, others are just gaining traction, still others just launching, and many are just trying to get noticed.

For example the portable CMM market is relatively mature given its 15-plus year run so far. Technical advances by the OEM’s for these products also are slowing, as probably are sales. Clearly there will be continued sales but most of the low hanging fruit, as they say, has been picked.

Meanwhile other 3D imaging categories, such as long range scanners and application-specific solutions, such as dental scanners, are very hot topics right now and sales are growing. I am fascinated by the recent growth in these areas and consequently we are watching closely for similar category killer apps (like dental) that have similar mass market potential. Think of it, there are 6 billion people on this planet and they all eventually need dental work where 3D imaging can help. We are working on similar body-related concepts where personalized shape capture enables individualized medical treatments as well as security and entertainment applications. See our new ShapeShot™ website for more on this.

Perhaps the most interesting aspects for our industry and for me are the technologies that are still flying under the radar. Being a ‘one-stop-3D-shop’ for nearly 15 years, we are often asked to test new 3D imaging technologies – both hardware and software – before they hit the market. Given our unique dual business model of providing both 3D services as well as product representation, we have a unique ability to match new solutions to old problems – or – we know where the holes are for potential market opportunities. This is one of our more valuable business assets and keeps us strongly leading edge.

2. What’s happening in the manufacturing and/or service area of the (medical, dental, auto, aero) scanning industry?

MR: In general for these industrial sectors we are noticing an increase in adoption and acceptance of 3D scanning as a increasingly common tool for solving technical problems. Clearly everyone in the industry is helping to achieve this adoption including the OEMs, other service providers, technical interchange groups, and users. The more awareness and promotion of 3D scanning technology, the more people will try it, come to accept it, and then eventually demand more of it. We in the industry already know that it works well and that it can help solve a lot of manufacturing problems; we just need more customers to understand this and fortunately this is definitely happening faster now.

3. How do the low/high cost scanning systems fit into the industry?

MR: Regardless of cost, most 3D scanners have a place in the proverbial toolbox. Price is usually NOT the most important factor for selecting a scanning system. That’s why at Direct Dimensions we use and sell so many different types of scanners. There is no ‘magic’ scanner (yet…!) that can replace all the various solutions offered by all the different OEMs. Clearly each technology has a place in the market, or they would not continue to exist for very long.

I have accepted this challenge for over 20 years – that is: constantly working to determine the best technology for every particular application. Today for example, with other like-minded experts within SME’s 3D Imaging Tech Group, we are working to categorize and classify the various 3D scanning technologies relative to applications. Our goal is to help demonstrate when and how all the technologies fit together, how they overlap, when & why to consider what technology, etc. So far we have compiled an extensive list of project characteristics, such as object size, color, geometric complexity, etc. In parallel we are working to identify a complete listing of all 3D scanning technologies with broad categorizations. This has indeed been a difficult task due to the complexity of the applications and the number of 3D solutions in the marketplace.

If anyone is interested in helping our SME 3D Imaging committee, of which I am the current chairperson, feel free to contact me directly for more information.

4. Do you feel scanning has achieved respectability as a needed process in the manufacturing world?

MR: 3D scanning technologies in the manufacturing world can be classified into three main use cases: 1) quality control, 2) reverse engineering, and 3) rapid manufacturing. The first two areas have been in use at some level for nearly two decades and are continuing to grow steadily. The third area – Rapid Manufacturing or RM, is relatively new and only just starting to reveal its potential.

There is no question that the scanning market for QC (dimensional inspection) is huge. Companies always want faster solutions for validating manufactured product and clearly non-contact scanning can provide this. Today’s primary method – the traditional CMM – has been around for over three decades and is therefore a mature and well accepted process. For non-contact scanning to disrupt this, the industry still needs maturity in the form of common performance standards, tighter delivery platforms, and integration to internal manufacturing quality procedures.

Reverse engineering, while sometimes controversial, is a legitimate process that allows a company to benchmark its competitor’s designs, convert legacy parts to digital formats, and capture hand-sculpted shapes for use within a CAD model. While the term for this process may not be the best, the technology has been proven to help in many different applications even beyond product design including 3D documentation for historic preservation, as-built architecture, and custom medical prosthetics, just to name a few.

Speaking of custom medical applications, I expect this area to grow substantially by means of rapid manufacturing, or RM. 3D imaging, combined with nearly 25 years of rapid prototype technology development, will come together to enable the long envisioned concept of mass customization. Products will be tailored specifically to individuals to provide custom fit medical orthotics, braces, protective gear, armor, even eyeglasses. RM will impact consumer products, security measures, medical appliances, and even our forms of entertainment.

5. What do you see on the horizon for the scanning and imaging industry?

MR: It’s my view that our industry is in a good position as it relates to the economy. Clearly the overall global economic situation is not great yet but 3D imaging technology is still relatively niche and early in its growth cycle compared to the much larger CAD industry, for example. Our major growth cycle is still to come.

Just look at the number of firms making and selling 3D solutions – there are well over a hundred worldwide. It’s like the car industry in the early 1900’s – lots of smaller companies that later consolidated into a few large giants. At some level this has started in our industry with some of the larger players, such as Hexagon, Leica, and Faro, making strategic acquisitions. We’ll have to see how that plays out given the economy but I think the small and mid size firms can have better immunity to negative global economic trends if carefully managed.

6. Which areas offer the most growth potential?

mR: The magic question - where does one invest for the future? You could follow current trends, which would indicate some of the growth topics discussed above, such as 3D microCT and conebeam CT technologies for medical applications, long range lasers for architectural and forensics, and automated scanning for manufacturing inspection.

At Direct Dimensions we hedge this uncertainty by working in virtually all possible directions for 3D scanning. This provides experience and perspective, and allows us to spot trends over time as the technology catches up to the problems.

Industry watchers should also take interest in the following industry indicators: contined growth in the number of conferences and events featuring 3D scanning including SME’s 3D Imaging, CMSC, SPAR, IAFMS, ASTM’s E57, and TCT; regular users meetings by many of the major technology suppliers such as PolyWorks, Geomagic, and Rapidform.

7. Where do you recommend learning more about 3D imaging?

MR: We promote and participate strongly in the following 3D imaging trade conferences. I encourage anyone interested in this field to attend these events:

* SME’s 3D Imaging conference at www.sme.org/3di
* CMSC at www.cmsc.org
* SPAR conference at www.sparllc.com

I also highly recommend this online forum which primarily deals with long range scanning: www.laserscanning.org.uk. This may be the most active technology-neutral networking site within our 3D field.

An industry friend of ours, Gene Roe, regularly publishes a great blog at lidarnews.com.

A growing source for collaborative discussion can be found in several relevant “LinkedIn” groups including:

* Portable CMM Users
* Laser Scanning
* White Light Scanning Pros
* International Metrology
* And new groups form regularly

We also receive a significant amount of 3D industry news delivered daily by newsletters from many vendors, trade magazines, online news sources, Google Alert news-bot emails, and RSS feeds. So feel free to inquire directly with any questions – we’ve probably read something about it.

We also regularly update our already extensive website with new materials at directdimensions.com, we post almost weekly to our blog at directdimensions.blogspot.com, we have published our newsletter every month now for over a year to nearly 50,000 subscribers; our YouTube channel features videos and animations from some of our more interesting projects, and now you can even follow us up to the minute on Twitter!

Thanks for a great 2009, our 15th year in business, and here's to a great 2010.

Michael Raphael
Founder, President, and Chief Engineer

Case Study: Using 3D Imaging to Create High-Res Prosthetic Hand

2010-01-08T11:19:00.007-05:00

Direct Dimensions has long been interested in applying our 3D laser scanning technology to aid in the field of “anaplastology,” the medical field of making cosmetic prosthesis which improve the quality of life for those who need them. We have worked extensively with some of the profession's most talented practitioners, including a long-standing partnership with the Johns Hopkins University School of Medicine's Department of “Art as Applied to Medicine.”

Some previous projects have included working with the team at Hopkins to help rebuild the nose of U.S. Army Senior Airman Michael Fletcher and working on many prosthetic ear projects. We consider the creation of prosthetics some of the most rewarding work we are privileged to do so we were very honored when Dr. Robert A. Erb, Ph.D, noted anaplastologist and former president of the American Anaplastology Association (AAA) contacted us to assist on a particularly challenging project.

Dr. Erb had a patient who had lost a hand in a tragic accident. The goal was to create a new life-like hand including the fine details of skin texture. The doctor was also interested in how 3D laser scanning might help with his methods. Through a recommendation from a colleague he found that Direct Dimensions and our Digital Modeling team was excited to take on the project.

DDI’s project manager Harry Abramson has worked on many similar replication projects and he noted the significance of this opportunity. “We were excited because it set a new benchmark for us to represent what could be done in anaplastology and realistic re-creation utilizing 3D scanning technologies. Our usual work generally does not need to be as detailed, but this time it was about creating the most realistic prosthetic possible.”

Dr. Erb came to Direct Dimensions’ lab with a plaster casting he had taken of his patient’s intact hand. We scanned this casting two different ways to ensure the highest quality of data possible: first with a laser line scanner mounted on a Faro Arm and second with a laser line scanner mounted on a motorized precision coordinate measuring machine, or CMM. This particular CMM system was integrated by our own DDI engineers for in-house projects requiring very high resolutions and can even capture fingerprints in 3D.

The resulting data from the scans was incredibly detailed, containing millions of 3D polygons. During the modeling process, utilizing PolyWorks software, the model was also flipped to create a mirror of the plaster casting and a faithful re-creation of the clients lost hand.

The high resolution 3D digital model was then provided to a rapid prototyping service bureau to create a physical hand using an Objet Eden printer - one of the highest resolution 3D printers currently available. The material selected was “Vero Blue,” a rapid prototype material noted for both its strength and its exceptional ability to retain fine detail.

The prototype prosthetic hand which we delivered to Dr. Erb was so lifelike that you could even see pores and hair follicles. Using the prototype hand, Dr. Erb created a finalized prosthetic in silicone with no loss of detail - truly an exceptional achievement, and one aided by the cutting-edge 3D technologies at Direct Dimensions.

3D Scanning Newsletter - December

2009-12-31T10:19:00.005-05:00

December's newsletter has been sent out and is also posted on our website.

Articles this month include:

How 3D Imaging is Changing the World: The last decade has seen some amazing advances in 3D imaging technologies, from the introduction of light weight, hand held systems to new advances in large scale scanners. With the technology evolving rapidly, we talked to our President and founder, Michael Raphael, about the current state of the industry and what innovations we can expect to see in the coming years.

VA Medical Center BIM: When Clark Constuction needed to include an existing building into a BIM (Building Information Model) they were creating, they turned to Direct Dimensions to help save time and money.

Football Player Digital Double: When tasked with creating a commercial for the AFL, Eye Candy, a commercial editing firm in DC, decided to use 3D animations based on a real person. Our team utilized many different scanning technologies and software to create a realistic digital double.

3D Scanning an Historic Sculpture

2009-12-28T16:25:00.002-05:00

This month saw the completion of major project that began, for us, in 2007.

The Genius of Connecticut bronze sculpture, standing eighteen feet tall, started its life perched at the top of the statehouse in Hartford in 1876. It was damaged in a hurricane in 1938 and subsequently placed in a storage facility, where it stayed until 1942 when it was melted down for the war effort. All that was left of the sculpture was a full size plaster model which was later coated in bronze and displayed in the lobby.

In 2005 the Connecticut State Legislature decided to recreate the original Genius of Connecticut sculpture in bronze and place it back atop the Capitol Building.

Direct Dimensions was brought in to 3D laser scan the eighteen foot sculpture in 2007. A 3D model was created from the scans and the model was used by Polich Tallix foundry to create a new bronze sculpture using traditional casting techniques.

Earlier this month, the completed bronze recreation was installed in its temporary home in the Capitol lobby. Check out the video below for footage of the sculpture being installed.

ShapeShot wins "Best Pitch" Award at First Maryland TechCrawl

2009-12-21T21:13:00.004-05:00

On December 16th, the Emerging Technology Center (ETC) of Baltimore held the first Maryland TechCrawl.

According to the ETC, "At the first Maryland TechCrawl, 21 local technology companies presented their products or services. The event drew people from the Baltimore - Washington, D.C. region, bringing startup companies, investors, executives, community connectors and local media together to forge partnerships, increase visibility and showcase the new technologies."

Direct Dimensions took the opportunity to present our new ShapeShot technology. It was a wonderful chance to get some feedback and refine our message.

The event also included a pitch competition where each of the 21 companies had 60 seconds to deliver their best product pitch/demo. At the end of the evening the ETC's board of directors chose the best pitch. We were honored to have ShapeShot chosen as the winning pitch.

It was a great event and we are looking forward to next year!

You can read more about the event here.

Case Study: Reverse Engineering WWII Jeep Frame

2009-12-14T13:29:00.003-05:00

DDI Vintage Jeep Frame Presentation 2008

View more presentations from dirdim.

Recently, Direct Dimensions had the unique opportunity to scan a 1940’s Bantam Jeep underframe. The Bantam BRC-40, alongside models like the Willys MA and the Ford GP, were among the first Jeeps produced by the U.S. Army. Due to their extensive use in WWII, they quickly became iconic of the war and of the era in general.

This particular Bantam frame, provided by client Todd Paisley, posed a challenging 3D problem, as it had rusted and corroded to the point where it was no longer usable. Direct Dimensions was brought in to reverse engineer the component in order to produce a digital model upon which new underframes could be manufactured.

DDI engineers Michael Lent and John Kelbel completed the scan in one day using a 12’ Platinum FARO Arm paired with the Laser Design SLP 2000 laser line scanner. The SLP 2000 proved ideal for this challenge, as its dual cameras and wide laser range reduce scanning passes, saving time while still ensuring high accuracy.

According to John Kelbel, the heavily warped underframe was scanned in sections from two separate positions, both from the front of the frame and from the back. These scans were then digitally combined using Rapidform software. Using Rapidform XOR software, the data taken from the scan was reverse engineered to produce a CAD model of the original ‘design-intent’ of this part suitable for manufacturing. The final deliverable allows the production of components based upon the historic Bantam underframe for several generations of Jeeps to come.

You can see additional documentation on the Jeep Reverse Engineering Project, including an interactive 3D model on our website.

3D Scanning Newsletter - November

2009-11-25T20:10:00.002-05:00

November's newsletter has been sent out and is also posted on our website.

Case studies this month include:

Reproducing a Rare Darwin Bust - In honor of the 150th anniversary of On the Origin of Species and 200th anniverary of his birth, the National Academy of Sciences commissioned a replication of a one-of-a-kind bronze Darwin bust.

3D Imaging Brings Robots to Life - 3D laser imaging technology helps rapidly create a digital CAD model of hand-sculpted robotic components for Hanson Robotics.

Monkey Skull Sculptures - 3D scanning of primate skulls helps artist create sculpture series

Click here to read the full newsletter.

If you have not subscribed to our newsletter yet, you can subscribe here.

Thankful in 2009

2009-11-24T09:13:00.009-05:00

Despite the economic challenges of this past year, Direct Dimensions has been fortunate to have had a very successful 2009 – our 15th year in business! In the spirit of the Thanksgiving holiday, we would like to express our thanks to:

Our great customers - thank you for entrusting us with your ships, your sculptures, and your airplanes and everything else you send to us, or send our team out to scan for you, including Northrop Grumman, Jeff Koons Studios, Carlson & Co, Lockheed Martin, FBI, Clark Construction, Harley Davidson, Nurad, International Truck, John Milner Associates, National Gallery of Art, Praxair, U.S. Army, U.S. Navy, and all of our other new and returning customers!

Our great vendors - thank you for providing us with top-notch 3D products and for all of your support including Basis Software, Dimensional Imaging, FARO Technologies, Geomagic, Innovmetric, Konica Minolta, Kreon, Laser Design, Pointools, Rapidform, Verisurf, and Vialux.

Our great employees - thank you for all of your creativity, initiative, dedicated long hours, last minute travel, and all of your hard work everyday. It is very much appreciated.

Our employee’s families - thank you for sharing your loved ones with us, probably more than you’d prefer.

Our friends and partners at SME, CMSC, SPAR, GBTC, ARC, Trilumen, and especially Mimic Studios, practically our L.A. office.

And a special thank you to Gene Roe for supporting us so often in his blog. Gene puts out a fantastic blog about the 3D scanning industry called Lidar News at http://lidarnews.com which everyone should check out.

And thank you all for reading our monthly newsletters and regular blog postings, and please have a wonderful Thanksgiving!

Digitally Preserved and Reconstructed Coffeehouse Now Complete!

2009-11-18T14:51:00.012-05:00

This Friday, November 20th is the grand opening celebration for the newly reconstructed Charlton's Coffee House in Colonial Williamsburg. It is the only structure of its kind, an authentic 18th-century coffeehouse, in the United States.

You can read about the events planned for opening day here.

Direct Dimensions was lucky to be involved as part of the pre-construction team, utilizing our 3D technologies to help document the coffeehouse's 18th century foundation.

To learn more about how, keep reading.

Case Study: Digital Preservation of Revolutionary Coffeehouse
In the summer of 2008, Direct Dimensions visited Williamsburg, Virginia to document the condition of the existing remains of an original ‘coffee house’ that George Washington was known to frequent.

This particular coffee house, owned by Richard Charlton during the 1760's, was one of several that had flourished in the area due to their popularity in London and abroad. Coffee houses of that time were known for more than their coffee, tea, and chocolate served to the colonials - they also hosted informal and spirited intellectual conversation. This activity made Charlton's coffee house one of Williamsburg's political and business ‘hotspots’ of the time.

DDI worked with the Colonial Williamsburg Foundation to laser capture what remains of the coffee house’s stone foundation. Of the original structure, only part of the brick foundation and some wooden fragments are still intact. We scanned the exposed foundation and the earthen floor with our Surphaser HSX spherical scanner.

This unique scanner captures extremely accurate and high resolution data over a medium-range (2-10 meters). The Surphaser is a non-contact laser scanner so none of the delicate centuries-old foundation was harmed during the data capture process.

The raw 3D ‘point cloud’ data gathered in Williamsburg was then digitally modeled back at the Direct Dimensions facility in Baltimore, Maryland. The final surface mesh model can be used to analyze the archaeological features found at the site.

Additional digital preservation projects:
Historic Site Scanning
Tomb of the Unknown Soldiers

Software Overview and Tips for Dense Point Cloud Processing

2009-11-13T09:56:00.002-05:00

Last month we posted a presentation that Michael gave at SME's Aerospace Measurement, Inspection & Analysis Conference on Reverse Engineering Airplane OMLs. One of the issues that often comes with large scan jobs, such as airplane scans, is how to handle massive amounts of 3D scan data.

At that same conference Michael and Peter Kennedy, our production manager and a specialist in processing data from large jobs, also gave a presentation on tips and software for dealing with dense point cloud data sets. You can view the presentation below.

DDI Dense Point Cloud Processing Presentation Oct2009

View more presentations from Direct Dimensions, Inc..

If you have any questions, feel free to contact us. We're happy to help!

TEDx MidAtlantic 2009

2009-11-06T13:39:00.005-05:00

We had a wonderful experience at TEDx MidAtlantic, meeting and talking to new people, exchanging ideas with them, and of course, imaging them in 3D with our new face imaging concept.

All of the speakers were thought-provoking, but we really connected with the presentation by the first ever CTO for the Federal government - Aneesh Chopra. Mr. Chopra spoke primarily about utilizing technology to improve peoples lives, particularly through medical technology and innovation. He even briefly talked about facial prosthetics which is a topic that has always been very important to us at Direct Dimensions.

Also, if you had a ShapeShotTM 3D face image taken at the event, you will be receiving an email shortly with a link to your very own personal website with your 3D face.

It was really a special day. Thanks to Dave Troy and all the TEDx MidAtlantic volunteers for making it all happen.

Direct Dimensions' President Michael Raphael poses two attendees for their ShapeShot

3D Model of Lincoln's face included in "Lincoln, Life-Size"

2009-11-03T11:27:00.009-05:00

Last summer we had the opportunity to scan an amazing piece of history: an original life mask of Abraham Lincoln cast in 1860 by Leonard Volk. The life mask is owned by the Kunhardt family, who are 5th generation Lincoln scholars, and was scanned for research purposes for a documentary they were making. You can read about the original Lincoln lifemask project here.

High quality renderings of the digital model made for the documentary have subsequently been used by Philip B. Kunhardt and Peter W. Kunhardt in their book Lincoln, Life-Size.

The book examines images of Lincoln's face, each page containing various portraits at life size. As the owners of one of the largest 19th century photo collections, the authors have a specific interest in comparing how Lincoln’s actual appearance fares against artistic renderings of the man, as well as the often-distorted daguerreotypes and photographic media of the mid-1800s.

Lincoln, Life-Size is being released today and can be purchased online or at a bookseller near you. If you want to see some incredible images, photographic and digital renderings, make sure to check out this book.

Additional 3D Lincoln reading:

Lincoln Memorial: Digitally Preserving America's National Monuments
Bringing Lincoln To Life in Night at the Museum: Battle of the Smithsonian

3D Scanning Newsletter - October

2009-10-31T22:18:00.006-05:00

October's newsletter has been sent out and is also posted on our website. This month we have some great case studies about scanning for documentation and visualization as well as some Halloween treats.

Case studies this month include:

Documenting Ancient Sculptures - Direct Dimensions traveled to University of Pennsylvania's Museum of Archaeology and Anthropology to document sculptures from their Ancient Egyptian Collection.

Archival Scan of Meteorite - The digital modeling team at Direct Dimensions 3D laser scanned the largest "oriented pallasite" meteorite ever found for archival and visualization purposes.

High-Res Human Skeleton - 3D imaging of a human skeleton helps a renowned medical illustrator create more accurate medical illustrations.

Click here to read the full newsletter.

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