3D replication of real objects using optical technologies

for reverse engineering and rapid prototyping.

1 2
Ján Èarnický , Dušan Chorvát jr.
1 - Faculty of Mathematics, Physics and Informatics, Comenius University, Bratislava
2- International Laser Centre, Bratislava

Introduction Fig. 1: Structured

The aim of this study was to demonstrate the possibility of Light-based 3D scanner
replication of a real-world 3D objects, based on capability of laser (Eyetronics),
stereolitography system to create a physical model from a data consiststing of structured
obtained from an object by non-contact 3D scanning device. light source (Speedlite
550EX flash with
Scanning and reconstruction customized objective),
PWe used the structured light-based 3D scanning system from and a professional
Eyetronics (Fig. 1), and a computer with the software bundles digital camera (Canon
ShapeCam and ShapeMatcher.
EOS D60 with 6 Mpixel
POur model (dimensions: 124.7 x 77.1 x 98.3 mm) was painted
by white-matt color before acquisition. CMOS detector)
Pthe 3D model was created from the set of photographs of the
object taken from different directions from the distance of 2 - 3 m with a Canon EF 70-200 mm zoom objective.
P The ShapeSnatcher Software was used to measure the deformations of the grid lines projected on the surface of the object
(Fig. 2), and to calculate the 3D structure of the visible part of the object (Fig. 3).
PAfter processing the model form different points of view, the resulting 3D-patches were stitched together (Fig. 4) using
the software ShapeMatcher, with which we created the complete 3D representation of the object having 39.000 triangles.

Fig. 2: Scaned object with Fig. 3: 3D patch computed Fig.4: Different colors
the shadow of the gird from 1 photograph represent different patches
Laser-induced photopolymerisation
PFor creation of replicas we used the LS-250 (NICTL, Shatura) laser
stereolitography system (Fig. 5).
PThe stereolitograph vat was filled with liquid photopolymer IPLIT-1 (epoxy
resin).
PFor laser induced photopolymerisation we used He-Cd laser LGK-30 (18 mW,
325 nm).
PThe effective size of structures that can be grown in the vat is
250 mm x 250 mm x 250 mm.
PThe thickness of slice was set to 0.30 mm.
PAfter polymerisation of the object on the platform we removed support
structures and post-curred the parts in UV chamber for about 30 minutes.
P3D virtual model was pre-processed with Magics RP software (Materialise) to
Fig. 5: The LS 250
define precisely the conditions and way how a real physical prototypes from
computer model would be manufactured by LS-250.
PAset of supports connecting the model to the stereolitographic platform was also generated (Fig. 7).
PThe thickness of the replicas was set to 2mm (model ratio 1:1), and 1mm (model ratio 1:2).

Conclusion
We showed that replicas of real objects could be obtained by applying laser stereolitography technique on
reverse engineered data of a real object (Fig. 6 and 8). Comparison of created replica (1:1 ratio) with original
object yield average deviations of 1.3 ± 0.8 mm, what reflects a mean relative deviation of replication (reverse
engineering/stereolitography) process of 3%. This value is in a good agreement with the values given by the
manufacturers of the epoxy resin (NICTL) and 3D-scanning system (Eyetronics) used.

Fig. 6: The object Fig. 7: Model prepared for Fig. 8: The replica
Production in Magics RP (Materialise)