Case Study: Documenting Ancient Egyptian Artifacts

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.

Case Study: The Awakening

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.

15 Great Projects Over the Past 15 Years

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.

Calling All 3D Artists

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.

Featured Project: KAL’s Virtual George W. Bush Head

Renowned cartoonist Kevin “Kal” Kallaugher came to Direct Dimensions with a caricature sculpture of George W. Bush’s head. His intention was to make a virtual, interactive puppet. Here at Direct Dimensions, we laser scanned and delivered a perfect 3D digital model of Bush to Kal so that his team at the University of Maryland Baltimore County (UMBC) could move into the next phase: animation.

With the help of UMBC’s Imaging Research Center, Kal was able to use the data provided by Direct Dimensions to create a system that makes the virtual Bush head move with the assistance of two human-controlled joysticks. The Walters Art Museum in Baltimore, Maryland, featured a retrospective of Kal’s work—Mightier Than the Sword: The Satirical Pen of KAL, which included the Virtual George W. Bush on display.

Product Focus: The Kreon Zephyr

The Kreon Zephyr scanner is ideal for scanning very small objects. It can be used as a digitizer on a laser scanner and features an accuracy range of 0.001”. Direct Dimensions uses this scanner in a wide range of projects, including the Virtual George Bush project, and highly-detailed work, like miniatures and engine blocks.

Training classes are available for this product, either in our offices, or yours. For further product and purchasing information, please download our Product + Service Catalog, or call 410-998-0880. Ask for Charlie Matlin for training class schedules and purchase details.