How to Make Your Own Custom Jigs and Fixtures
How to Make Your Own Custom Jigs and Fixtures In the world of manufacturing, precision and efficiency are paramount. One of the key tools that help achieve these goals are jigs and fixtures. These essential devices hold, support, and secure products during various processes, ensuring consistency and quality. Traditionally, creating jigs and fixtures could be time-consuming and costly, but with the advent of 3D printing, manufacturers now have a powerful tool to produce these aids in-house. Understanding Jigs and Fixtures Jigs and fixtures might sound similar, but they serve distinct purposes. Jigs are tools that hold the workpiece and guide the equipment to ensure proper alignment during operations like drilling or milling. Fixtures, on the other hand, are devices that hold the workpiece in place during secondary processes such as welding or assembly. Both are crucial for maintaining high part quality and operational efficiency. The Advantages of 3D Printing 3D printing has revolutionized the way manufacturers approach the creation of jigs and fixtures. Here are some of the key benefits: Customization: 3D printing allows for the creation of highly customized jigs and fixtures tailored to specific parts and equipment. This level of customization ensures a perfect fit and optimal performance. Cost Reduction: Producing [...]
Golden Gate Bridge Replica: Crafted with 3D Scanning and Geomagic Design X
Golden Gate Bridge Replica: Crafted with 3D Scanning and Geomagic Design X San Francisco’s landmark captivates people. “Everyone who visits San Francisco goes to see the Golden Gate Bridge. They want to see it from all sides and always to be close,” says 3D scanning specialist Marcio Adamy. He’s also enchanted by it. “Every time I go back to the bridge, which is often, I learn more about it. I’ve learned about the people who work there and their love for it. They call it ‘Goldie’. And that rubbed off on me too. I love the bridge. I think it’s an amazing place. This is why I decided to scan the monument,” he says. Adamy refers to an art piece near one of the bridge’s foundations, shaped like a slightly squished pillar. Built in 2013, it uses original material and is painted the same color. Reverse Engineering Challenge Most see the object as an artistic tribute. Adamy saw a reverse engineering challenge and created a miniature 3D-printed memento of the bridge. He used an Artec Leo scanner, stored in a backpack he loves. “I could not reach certain areas with the scanner due to the angle and field of view. If I put [...]
Understanding Refresh Rate in SLS 3D Printing
Understanding Refresh Rate in SLS 3D Printing Selective Laser Sintering (SLS) 3D printing is a powerful technology that allows for the creation of high-quality, industrial-grade parts. One of the key factors in achieving optimal print quality and efficiency with SLS printers, such as the Formlabs Fuse Series, is the refresh rate. The refresh rate refers to the ratio of new powder to recycled powder used in each print cycle. This balance is crucial because it impacts both the material properties of the printed parts and the overall cost-effectiveness of the printing process1. The refresh rate is adjustable, allowing users to fine-tune it according to their specific needs and workflows. For instance, a 100% refresh rate means using entirely new powder, while a 0% refresh rate would use only recycled powder. However, using recycled powder over many cycles can degrade material properties, so finding the right balance is essential. Formlabs provides recommended refresh rates for their SLS powders, but users can tweak these settings to optimize their processes1. Choosing the right refresh rate involves considering several factors, including packing density—the arrangement of parts within the build chamber. Higher packing densities mean less unsintered powder, which can be recycled more efficiently. For example, if the packing density is [...]
Swing Bridge Reverse Engineering Simplified with Geomagic Design X
Swing Bridge Reverse Engineering Simplified with Geomagic Design X A swing bridge in a coastal dock system was decommissioned after being twisted. A ferry company needed it operational for car parking but faced a dilemma: closing the bridge to test it could jam it if it wasn’t functioning. Unable to test physically, they created a digital twin using a long-range laser scanner and simulated the bridge’s motion if closed. Scanning a swing bridge This approach, led by OR3D and Service Manager Robert Wells, used a Trimble X12 3D Laser Scanner to capture the bridge’s details and Geomagic Design X to create a CAD model for simulation. A two-person team completed 120 high-definition scans in one day. The data was checked in Trimble RealWorks and uploaded into Geomagic Design X, where Sean Kean modeled the bridge and its components. Accuracy of the essence Modeling and data processing took a few days due to complexity. “Once we modeled the bridge in Design X, we ran the simulations, and saw the bridge was going to collide in a certain position,” Kean explains. “That gave the company the confidence to try it for real.” The simulation predicted a two-to-three-millimeter collision, confirmed in real-life. “We wouldn’t have been [...]
What’s New with Shining 3D Scanners
What's New with Shining 3D Scanners Einscan HX and HX2 (Reverse Engineering) The HX is an excellent scanner for reverse engineering. For the scanning and reverse engineering of many part sizes and shapes, the Einscan HX (and soon, the HX2) are an excellent choice. Stay-tuned for HX2 info. when it becomes available. The HX and HX2 are hybrid scanners. While holding 40 micron total tolerance in laser mode, this scanner model can also scan using structured light and can capture color/texture. Freescan Combo | Combo Plus (Reverse Engineering and Inspection) Roughly the size of a cell phone, the Combo and Combo Plus are excellent for both metrology and reverse engineering. The Combo Plus offers roughly double the scanning speed over the Combo. These are both metrology-grade scanners, offering 20 micron accuracy and up to 50 micron resolution. When used in HD mode, these scanners can create a single scan with multiple resolutions captured. So when scanning an object that has a specific location with high detail, the Combo or Combo Plus is ideal for capturing both sets of features in a single scanning session. Additionally in IR mode, this scanner does an incredible job at scanning organic shapes and since it [...]
Design X Go – Reverse Engineering for Mastercam has arrived!
Design X Go – Reverse Engineering for Mastercam has arrived! The ‘Bridge’ from Scan or Point Cloud data to fully machinable models in Mastercam If you’ve ever programmed a Step file that was ‘AutoSurfaced’ from a mesh or point cloud, you’ve likely experienced the many challenges associated with this process. Design X Go supports traditional CAD modeling capabilities to generate the most basic, 2-axis part to the most involved, multi-axis part, from scan data. From Mesh to Part to Mastercam’s pocketing toolpath to ‘clean’ 2-Axis code! Same capabilities in the surfacing and multi-axis environment! From Mesh to Part to Mastercam’s Blade Expert toolpath to ‘clean’ 4-Axis code! Register for our Webinar on October 29th, 2024. 10:00 AM - 11:00 AM EDT to see how Design X Go can provide outstanding reverse engineering capabilities for designing and programming parts when you don’t have a CAD model. Register Today