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.

Featured Project - Digitally Preserving the Lincoln Memorial

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

(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

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

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

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

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

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

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

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.