Case Study: Scanning the Wright Brothers Propeller

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.

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.

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

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

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

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 an Historic Sculpture

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.

Case Study: Reverse Engineering WWII Jeep Frame

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.

Digitally Preserved and Reconstructed Coffeehouse Now Complete!

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

Utilizing 3D Scanning for Historic Preservation

At Direct Dimensions we are using some new technologies that we believe are a perfect fit for preservation applications not only because they are fast and highly accurate, but because they are also non-contact methods of acquiring massive amounts of data that can be used for documentation, restoration and preservation.

The Druid Hill Arch is a perfect example of how our team was able to collect highly accurate data of a large monument in less than a day.

Step 1) A team of Direct Dimensions engineers and team members from John Milner Associates arrive on-site at approximately 8 AM to begin set up. Within thirty minutes they are ready to start scanning the arch.






Step 2) Using the portable Surphaser HSX Spherical Scanner the team was able to take over 20 scans in the next few hours. The Surphaser is perfect for architectural preservation projects because it can be taken anywhere (it can be carried on a plane) and is made to quickly and accurately scan mid-large range objects such as planes, vehicles and buildings.




Step 3) Our team finished scanning/data collection and was back in our office, aligning all the data by close of business the same day.







Step 4) Initial deliverables include plan views and elevations, but the data can also be used for physical reproductions, animations, renderings, virtual environments or anything else you can think of.





Stay tuned! We're still working on the Druid Hill Arch and are excited to show some of the 3D visualizations we've been working on.

3D Laser Scanning Historic Druid Hill Park Entrance Arch

Direct Dimensions, Inc. in conjunction with John Milner Associates will be in Druid Hill Park this morning, June 30th, 3D laser scanning the old Madison Avenue Entrance Arch to Druid Hill Park. The 3D scan data will be used to restore the arch, part of an on-going, park-wide restoration project.

About the Arch:
• The park itself is one of the three oldest landscaped urban parks in the country (along with Central Park and Fairmount Park in Philadelphia) and is on the National Register of Historic Places.
• The entrance was completed in 1868 and served as the main entrance to the park until it was separated from the park proper by the completion of Druid Park Lake Drive.
• In 1961 the arches, declared to be a traffic hazard, were almost torn down. $14,000.00 dollars were raised for the preservation of the arches and demolition was avoided.
• Almost 50 years later the restoration efforts are finally beginning.

3D engineers from Direct Dimensions and preservation specialists from John Milner Associates will be on-site at the Druid Hill Arch today from 8 AM to 1 PM, scanning this piece of national history.

We invite anyone who is interested to come down (Madison Ave and Druid Park Lake Drive) and view the scanning/documentation process. We’re happy to answer any questions and talk about the project.

WJZ 13 Broadcast Featuring Direct Dimensions

In case you missed the show yesterday, WJZ 13's piece "Direct Dimensions Transforms Our Digital Universe," can be found below:

To see the story on WJZ, please visit Direct Dimensions Transforms Our Digital Universe.

DDI on WJZ Channel 13 Newscast Tonight!

above left: Direct Dimensions' Original 3D Polygonal Data. above right: Still from Night at the Museum: Battle of the Smithsonian © 2009 Twentieth Century-Fox Film Corporation.

We just wanted to let all of our local friends and family know that Direct Dimensions will be featured on the WJZ Channel 13 newscast on Monday June 8, 2009 during both the 4:00 pm and 5:00 pm news.

Reporter Ron Matz visited our facility to cover our work with the Lincoln Memorial and subsequent involvement in the blockbuster film Night at the Museum: Battle of the Smithsonian. We also had the opportunity to scan Mr. Matz and showcase our new 3D face and 3D body scanning technologies. It is an exciting time to be working in 3D technologies! Please watch and let us know what you think.

For those of you that aren't in the Baltimore area or aren't able to catch it the first time around, stay tuned. We'll post the clip as soon as we have it.



Ron Matz from Baltimore's WJZ Channel 13 News shooting the introduction at Direct Dimensions on Monday June 8, 2009

PBS Motorweek Talks Biodiesel

Direct Dimensions' work with Biodiesel University was featured on the PBS series "Motorweek." Direct Dimensions laser scanned and digitally modeled the bus interior to help Biodiesel University visualize the space planning of the Mobile Lab.

This episode reported on the alternative renewable fuel biodiesel. Other episode highlights include an "apple seed" hot water tank conversion, a local biodiesel co-op, and an overview of what biodiesel fuel can do, and why "homebrews" feel it's an important step in moving away from traditional fossil fuels.

You can see our Animated Walkthrough around minute 3:25 of the video!

More about Biodiesel University here.

View our Biodiesel University Featured Project here.

The full segment will air again this Thursday March 19 at 8pm on PBS and MPT.

Five More Patriotic Projects

We had a blast pulling together January’s “Presidential” newsletter but even we were overwhelmed by how many important projects we’ve worked on in the realm of American history. We couldn’t fit them all in our newsletter so here are five more that we love, in reverse order:



5. 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, France on this anniversary weekend, the completed bell was returned to the U.S. and now rests in Philadelphia.



4. Louis XVI Portrait Frame - DDI had the opportunity to scan a priceless painted portrait frame that had been gifted by France's King Louis XVI to George Washington. A representative section of the ornate frame was 3D laser scanned and the resulting data was digitally modeled into a format suitable for replication. A foam prototype of the frame was produced initially and a milled replica is to be created some in several different materials.



3. “Young Ben” Franklin - DDI laser scanned a three-foot tall bronze bust of a youthful Ben Franklin. The sculpture, which is displayed in the University of Pennsylvania's on-campus bookstore, shows the founding father as a young man. The data captured in the laser scan was digitally modeled and used to produce high resolution prototype miniatures of the bust. These prototypes were then used as casting patterns for 8" and 12" bronze replicas.



2. 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.



1. Riding In Style – And for the neatest Presidential-related project, in late 2004, DDI scanned the inside seating area of a unique, highly armored vehicle in Washington, D.C.. We'd love to spill our secret further because this was seriously one of the coolest projects we’ve ever done, but we’re not allowed to say any more about this particular project – for obvious reasons.

You can read about more projects here.

Preserve, Conserve, Restore

Lately, one of the buzzwords here at Direct Dimensions has been “preservation.” We've had our hands full with challenging and unique projects to conserve and replicate historical treasures. Last week, we worked on a project for the US National Park Service, and we also had a team of engineers on location at the Corcoran Gallery of Art in Washington, DC.

We believe that our innovative 3D technologies are perfectly suited to preservation applications not only because they are fast and highly accurate, but because they are also non-contact methods of acquiring data for posterity. Previous methods of preservation, such as making castings for replication, have required the application of wax or plaster and pressure that might cause damage to the often-antique item being restored. These methods are often expensive and require many hours of hand-finishing to create a reasonable facsimile. Using 3D laser scanning, DDI can collect that data quickly, and without any physical damage to the subject. Digital modeling can restore details which time and nature have eroded. More than just a close copy, DDI can also provide the data to make an exact replica in a wide selection of materials.

As we are committed to historical preservation, DDI has worked on many digital conservation projects over the years. We have scanned the Lincoln Memorial in Washington, DC, as well as the Tomb of the Unknowns at Arlington National Cemetery, architectural elements of the Maryland State House, and even the Liberty Bell itself. For more information on our efforts towards historical preservation, check out our project portfolio on art and architecture!