Proposal

No annual report

Introduction

Proposal ID 2015-033
Submitted January 16, 2015
Owner jimified
Department DXArts
Category Collaborative
Funding Status Fully Funded
Metric Score None

Contacts

Primary
  • Name
  • Title
  • Email
  • Phone
  • Mailbox
  • Jimmy Johnson
  • Research Scientist
  • jimified@uw.edu
  • 2062808228
  • 353414
Budget
  • Name
  • Title
  • Email
  • Phone
  • Mailbox
  • Juan Pampin
  • Director DXARTS
  • pampin@uw.edu
  • (206) 616-6258
  • 353414
Dean
  • Name
  • Title
  • Email
  • Phone
  • Mailbox
  • Ron Kline
  • CDoC
  • arkline@u.washington.edu
  • (206) 543-6366
  • 353765

Descriptions

Abstract

Students making use of the both the Mechanical Engineering Shops and DXARTS Ballard Fab Lab would greatly benefit from a tool for validating designs manufactured in-house and for reverse-engineering existing objects to make improvements, and manufacture them in better ways. For students in the arts, the ability to instantly digitally capture any object in three dimensions in full color has limitless creative potential. These labs are used by hundreds of students and multiple clubs, some of which compete on a national level. The Creaform HandySCAN 700 in combination with the Vxmodel software provides a convenient solution for students to scan any given component and import the resulting image into a computer aided design (CAD) suite. Advanced feature recognition technology used by the laser scanner is capable of detecting line dimensions and rotations, to name a couple, making it easy for students to convert the scanned data into file formats suitable for CAD environments. The HandySCAN provides students with side-by- side comparisons of components modeled in CAD before and after manufacturing for accuracy and safety concerns. It also exposes the students to advanced technology that has become an industry standard, making it an excellent learning opportunity.

Category Justification

The proposed hand-held scanner will improve the manufacturing capabilities of the

Shops, labs and clubs. It will streamline the manufacturing process employed by all

students who routinely Mechanical Engineering departmental resources for club,

academic and research projects.

Background

Students interested in design and manufacturing of structural materials and

components regularly use the Mechanical Engineering Student shops for

professional tooling and instruction. Machining equipment includes multi-axis mills,

lathes, welders, grinders, and CNCs made available for UW class projects and

student-run organizations such as the Formula SAE, Human Powered Submarine,

and EcoCAR teams. This center provides a hands-on manufacturing environment for

classes like ME 355, in which a sterling engine is produced from aluminum ingot,

and has been vital to the to success of the aforementioned student organizations.

Formula SAE has been a top-20 competitor for the past 10 years taking first

internationally in 2013, and the EcoCAR team placed second at the 2014

competition in its first advanced vehicle technology competition.

Recognizing the growing manufacturing needs of students within the ME

department, the Mechanical Engineering Student shops have grown to meet the

demand bringing in more tooling such as 3-D printers and a large automated

machining table. Yet, the Students would like to incorporate a hand-held laser

scanner to reverse engineer undocumented components and validate designs made

and manufactured in-house. The hand-held scanner is produced by Creaform and

includes a post-treatment software package allowing the images captured to be

directly imported to a wide variety of CAD suites such as SolidWorks and Siemens

NX8. Scanning any given component takes under five minutes, and the resulting

image is a three-dimensional representation that includes feature recognition like

extrusions and fillets. The resulting image is a better representation over similar

scanners due to the advanced feature detection of the scanner allowing for easy

component manipulation once the image is ported to a CAD suite. This is crucial. As

a result, components can be designed and soft-validated in CAD before

manufacturing and then validated again by scanning the manufactured end-product

such as a composite wheel. The comparison between design and manufactured

products serve as a great learning opportunity to improve design and

manufacturing processes.

The scanner of interest is the Creaform HandySCAN 300, which includes the

Vxmodel software with a five-year license to port data collected into various CAD

suites. Traditional hardware packages cost $38,610 for the scanner, and $2,940 for

the Vxmodel software. The software blends well SolidWorks predominantly used by

the ME department and NX8.0 used by EcoCAR.

Benefits to Students and the University

Laser scanning technology is quickly becoming an industry standard for tracking

physical characteristics of any system, industrial or otherwise. Experience with this

technology will provide students with another industry-prevalent technology and

assist ME students in comparing designs produced in CAD with scanned

manufactured components. This is crucial to understanding and streamlining a

manufacturing process as well as improving safety factors of designed components.

At the present time, students validate safety rating using Instron testing and

computer aided simulation. Being able to compare contour, for example, of a part

designed in CAD to the actual manufactured component serves as another means of

design validation by ensuring the manufacturing process is executed professionally

and as intended. Typically, it is human error in the manufacturing process, such as

composite structure lay-ups, that leads to unanticipated and low safety ratings.

Contour comparisons help in this regard by juxtaposing physical features of a design

against its finished product produced in the MIC.

In addition, the laser scanner serves as a convenient solution for gathering CAD data

from components with none provided. Scanning of parts such as automotive

interiors or various engines will provide invaluable CAD data. This may speed up the

packaging of certain components in a larger system, for in some cases proprietary

CAD data is not made available before the manufactured product is. A great example

of this is a General Motor engine.

Departmental Endorsements

The addition of a highly accurate handheld 3D scanners would drastically improve the abilities of our student shops. Along with expanding the curriculum of our class labs, they would also support all of our technical clubs, helping them speed up their prototyping and reverse-engineering processes.

Eamon McQuaide
Mechanical Engineering Shop Supervisor
UW Mechanical Engineering Instructional Shops

Installation Timeline

There is relatively no installation time. Simply install the Vxmodel software, and

begin scanning.

Resources Provided by Department

The Mechanical Engineering Student Shops will house and maintain the scanning

equipment. The Mechanical Engineering Department’s full time shop staff will assist

interested students in the operation of the new equipment.

Access Restrictions (if any)

The UW student machine shop is accessible to all students, staff, and faculty of the

University of Washington. Its normal operating hours are from 8:30AM to 4:00 pm

on Mondays, and 8:30 AM to 8:30 PM Tuesday through Friday. Some labs are taught

within this time frame, and they do hold priority over machines at that time, but

they account for a very small portion of the overall time available to anyone who

chooses to use the shop. A graduated safety and training program is in place to

certify entry-level users of the shop, and one-on one training and support is

available to them in their pursuits to use more powerful and complex tools. There

currently for-credit courses available through the Mechanical engineering

department (ME355, ME409) that include the shop training in their curriculum.

These provide a more structured and in-depth application of the technologies and

theory behind the manufacturing and CNC machining topics. Shop safety classes are

held at the beginning of every quarter according to student demand. The classes are

currently free, but may eventually require a maximum onetime fee of 50 dollars for

a 1 credit course. These fees will pay for the upkeep of the equipment we currently

have in the shop, and help pay for community tooling and other consumables

available to the students at no charge. Any Mechanical engineering clubs such as the

formula and Sub teams listed above will also include the shop charge in their lab

fees. This is still far cheaper than any other shop certification course on campus (as

far as we are aware the next closest course is through applied physics at $150), and

at this point the only other shop available to all students.

Student Endorsements

Portable 3D scanners have clinical capabilities in prosthetics and orthotics. Normally, practitioners take casts of a patient’s limb, fill the cast with plaster, and work on a physical mold to fabricate an orthotic or prosthetic device. This process can take more than an hour from cast to a modified plaster model. However, 3D scanners have been recently integrated into the field. A limb can be scanned and modified in the software in under 10 minutes with proficient use of a scanner. The use of 3D scanning in prosthetics and orthotics is rapidly increasing. However, the Department of Rehabilitation does not have access to a 3D scanner. Master of Prosthetics and Orthotics students would benefit greatly from having a portable 3D scanner available to trial, to better prepare for a clinical setting.

Christina Minh
2nd year
Master of Prosthetics & Orthotics (MPO)

As a Junior in the Mechanical Engineering Department and Administrative Director of the UW Formula Motorsports Team, I have begun to realize the growing importance that student groups are to a well-balanced curriculum Both the Formula SAE Team and EcoCar Team support the growing demand from employers to have students entering the workforce already having some prior experience on a team and in an engineering-environment. The teams use many tools and equipment to help validate their designs, and a 3D Scanner would be a great new addition to the ME Shop. The current shop does not have the necessary capabilities for students to scan or reverse-engineer different parts, and a HandySCAN 300 would help tremendously. In addition, a large portion of the department’s student body participates on the Formula SAE Team and EcoCar 2 Team, so this piece of equipment would be used by a large number of students.

Andrei Arevalo
UWFSAE - Administrative Director
The Boeing Company - Payloads Interiors Design Engineer Intern

As a senior in the Mechanical Engineering Department I have been in many situations where having a 3-D scanner to get CAD files for objects would have been extremely valuable. There are many instances where companies will not provide CAD models for products which we try and incorporate into our designs and having a STL model which can later be exported to a solid / surface would be very useful. Also one aspect of FSAE is design for human interactions & ergonomics. Having a scanner to have accurate representations of human body parts would be very valuable for design parts of the car such as the steering wheel, pedals & seat.

Zach Stoddard
UW BSME ‘15
UWashington FSAE
T24 | Enging/DTM
T25-T26 | Technical Director
zstoddar@uw.edu | (206-245-7468)

Measuring is an essential part of the process of validating a design. The measuring equipment currently available to students in the Mechanical Engineering machine shop is extensive. However, because the current equipment is only intended to make consecutive individual measurements, it is not practical to measure large areas at high resolution. The proposed 3D scanner would allow students to quickly measure parts with unparalleled coverage and resolution, and to validate designs more effectively.

Sam Crow
UWFSAE

As a Sophomore in the Aeronautical engineering program here at the University of Washington, every day I witness the need for creating models of already existing objects. Though general dimensions can be easily modelled by a skilled designer, creating detailed designs using physical measurements is both cumbersome and tedious. Having a 3D scanner that can easily feed us these details will allow the UW FSAE team in particular improve our potential for creating large assemblies without investing too much time. Allowing us to reverse-engineer parts in this fashion will surely help the UW FSAE team in future competitive success; as well as help students implement engineering technology in their educations.

Mark Subbotin
UW FSAE
Kirsten Wind Tunnel - Test Engineer

As a two year member of FSAE at UW and a junior in the ME department, I can attest from my own experience how important hands-on learning is to the development of well-rounded and effective engineers. Today’s industry is in high demand of graduated engineers that have experience with technology like the HandyScan 300. The machine shop is currently equipped with many machines that give students experiences critical to their development, but currently lacks tools that allow for students to reverse-engineer parts. For this task a tool such as HandyScan 300 is vital, and it would be a huge benefit to the students and the department to have such capabilities available to us.

Jake Mutter
Junior - ME department - UWSAE
jake.mutter64@gmail.com

As a member of UWFSAE, I can confidently say that the team requires an instrument to accurately model existing objects. While general attributes can be measured by hand, detailed measurements necessary for recreating the design using CAD software requires much greater precision and dexterity than what we are currently capable of. Thus, having a 3D scanner would drastically increase our ability to reverse engineer these parts and provide learning opportunities for members on the team who are using this hardware.

Kevin Luo
Sophomore - EE department
UW FSAE

As a sophomore in the Mechanical Engineering Department and a member of the UW FSAE team I know firsthand how useful a 3D scanner would be for our team, as well as many other student organizations. During our design process we create a CAD model of our entire vehicle assembly but it is time consuming and impractical to create detailed models of some components that we buy off the shelf. Having a handheld 3D scanner available in the ME machine shop would allow us to scan complex parts and import them directly into our CAD assembly, saving us time and effort. Another area where this scanner would be incredibly useful is in the design of ergonomic components on our cars, such as the seat and steering wheel. We would be able to generate complex contours that match the geometry of our drivers and improve the overall ergonomics of our cars significantly. In short, the Creaform HandySCAN 300 would be a great addition to the ME machine shop and an invaluable tool for many student organizations.

Julian Powell
Sophomore - Mechanical Engineering
Aerodynamics Lead - UW FSAE

Having the ability to accurately describe parts which have already been manufactured through various measuring techniques has long been an essential need for engineering practices. Measuring is essential in order to validate a part design. Currently, the equipment available to Mechanical Engineering students, the FSAE team, and the EcoCar team is well-developed, but could be improved. The current equipment is only meant to be used for consecutive individual measurements, and it is not practical for use in measuring large areas with very high tolerance features. The proposed 3D scanner would allow students to quickly measure parts with much greater speed and coverage, as well as resolution. Having this capability would allow designs to be validated more quickly and effectively, and accelerate the iterative design process.

Kevin Schram von Haupt
UWFSAE

For the University of Washington’s Formula SAE team, precision is of the utmost importance. The HandySCAN 300 would allow us to ensure manufactured parts and purchased components, accurately match what we have as a 3D CAD model. A specific use would be to get an accurate model of our carbon composite chassis after it has been manufactured. It is a large piece and is hard to make perfectly, but the suspension components that mount to it require great accuracy. Having this technology would allow us to ensure components are mounted properly, ultimately affecting the performance and reliability for the vehicle. The more technology we have access to, the more we can delve into designs and develop as engineers.

Ryan Wolfe
Senior - Mechanical Engineering
UW FSAE

As a 3rd year student engineer on the University of Washington Formula SAE team, I have witnessed the challenge each year to design around an engine for our car. Our goal as a team is to produce world-class FSAE racecars in a safe, justified, and extremely educational fashion. The acquisition of the HandySCAN 300 would only aid in our pursuit of these goals. We would be able to scan the engine and get an accurate and useful featured model that we can then design engine mounts, cooling systems, shift systems, intake/exhaust around with confidence that our model has a high level of fidelity. The use of such a tool would not only increase safety and reliability of our car, it would prepare the department’s students with a competitive edge in the industry, an edge which is becoming more and more important.

Zachary Piercy
Senior - Mechanical Engineering
UW FSAE

Students in the ME department would greatly benefit from a 3D scanner. During the Formula SAE design process, it is necessary to have CAD models of components that we purchase, such as the engine. When these components contain complex features and geometry that must be mated to by student-designed parts, it is important to have an accurate model. Having the HandySCAN 300 would be a huge help in this regard and would enable us to have accurate models of any intricate parts.

Jason Granger
Senior - Mechanical Engineering

As a second year member on the Formula Motorsports team, I have seen that there are many parts on the car (i.e. engine,seat, etc) that due to their complexity are not practical to model using traditional methods. A 3-D scanner would allow our team to have accurate CAD models and better enable us to perform complex analysis on engine mounting and vibration isolation. As well as iteratively design parts that influence driver ergonomics.

Ryan Scuderi
Senior- Mechanical Engineering
UW FSAE

Having a 3D scanner at our disposal would really help us extend our capabilities for reverse engineering and prototyping. Being able to import accurate models into the car would help us as well as future teams reference an accurate design. An example of a use for a 3D scanner would be improving driver ergonomics by scanning prototype seats or steering wheels to allow them to be modified. Components like seats can contain many complex curves that are difficult to model and more effective to prototype by hand rather than guessing dimensions. A more resourceful and efficient way of creating prototypes could be to start with a base seat carved out of foam and shaving or cutting contours into the seat to best suit the preference of the drivers. Once the driver is happy with the shape, it could then be scanned and produced in its final form with lightweight composite materials.

Bryan Lin
Junior - Mechanical Engineering
UW FSAE

Acquiring a 3D scanner would allow our team to greatly improve our capability to reverse engineer parts and improve the accuracy of our CAD models. Creating detailed models of parts that we buy is inefficient and time consuming and getting details about the parts through scanning would allow us to create our models more effectively. Also, hands on learning is critical to the development of engineering students and access to technology like the HandySCAN 300 would provide an invaluable benefit in terms of implementing engineering technology in our education.

Abel Bantiwalu
Sophomore - Mechanical Engineering
UW FSAE

On the Formula SAE team here at UW, we design race cars from the ground up. This is an extremely challenging task as well as a lengthy process. In many ways, this phase of the year-long competition cycle we run on allows us to forsee the challenges facing us in future months of manufacturing as well as in future years as a club. The 3D scanner will ease the challenges of properly designing based on some of the components of the car that we cannot easily model. This especially includes anything that the driver directly interfaces with--for example we can use the 3d scanner to more effectively produce the ergonomic systems on the car. In addition, we can use it for reverse engineering and analysis of dynamic systems on the car. As an educational tool alone, this 3d scanner would be an invaluable addition to the tools we already use on a daily basis.

James Lindsay
Junior-Mechanical Engineering
UW FSAE

As a student engineer who recently joined Formula SAE and who has been interested in engineering and robotics for over 6 years, I find this 3D scanner not only fascinating but essential to our continuing development and success. I believe that acquiring this scanner would vastly increase the scope of our engineering knowledge gained through our participation on the team by allowing us to create a multitude of new and improved parts and prototypes. I believe that the basis behind the scanner (being able to scan a real object and import it into CAD) will not only make our work much easier but it will make it more realistic because we will be basing our models off of a tangible object rather than just model drawings, essentially allowing us to reverse engineer parts and make minor modifications rather than start from the ground up on every part, every year. I think that this scanner will be invaluable to not only Formula, but other student-engineering clubs at the UW as well.

Steven Bell
Sophomore-Mechanical Engineering
UW FSAE

As a sophomore in mechanical engineering who is new to Formula SAE team, I can see numerous benefits to having the option to use the Creaform HandySCAN 300. I have used 3-D scanners before and I think this is on piece of equipment that believe is valuable for engineers to get experience with or at least learn how to use. I can’t imagine how much time would be saved when creating a CAD model of parts or equipment that we do not already have on a CAD file. This would also be helpful when in the test phases of projects. We would be able to scan items before and after test and see physical deformations from tests. This will be a valuable tool for documenting test results.

Daniel Castronovo
Sophomore-Mechanical Engineering
UW FSAE

A handheld 3D scanner would be invaluable to the EcoCAR 3 team, as it would allow us to accurately reverse engineer any number of hard to model components in CAD.

Troxel, Sylvie

I love CAD, but having a 3D CAD scanner would allow me to learn a lot
more about the software itself. Reverse engineering what's already been made is a fantastic way to experience engineering in its purest form, and understanding the more complex models in CAD without the barrier-for-entry that they bring can be a gold mine of information.
Gianelli, James
CreaForm's portable 3D CAD scanners would hasten the productivity for
the EcoCar team members who utilizes CAD programs. The physical
dimensions of any components can be quickly scanned and imported
into a virtual CAD environment within a short period of time for
modification, replication, or educational purposes. I endorse this
product, because I am a CAD user myself along with my team members
and would no doubt benefit from the time-saving apparatus.
Ngo, Jeff
A 3D CAD scanner would be very useful to our team, because it would
allow us to quickly obtain dimensions of parts we are going to replace
on the EcoCAR to ensure that the new parts will have the same profile.
This technology can also be used to update existing parts. We could scan
an assembly and then replace newly designed parts with old ones to see
how they fit before they are actually constructed.

Albin, Greg

On my second day of work at Microsoft last summer, I attempted to
make an animatronic of Olaf, the lovable snowman from the Disney
movie Frozen. For eight hours, as very prestigious researchers walked
through the hardware lab, I sat at a bench carving away foam. Eight
hours later, I had a vague shape of Olaf's head, an embarrassment of a
day's work, and no animatronic. If I had a 3D CAD hand scanner, I would
not have wasted 8 hrs.

Tran, Tracy

If I had a hand scanner I could perform critical design reviews of parts of
our system in 1/20th the time it would take without it.

Kong Andy

This revolutionary technology would greatly help EcoCAR accomplish
any goals of 3D modeling. 3D scanning is part of the forefront of
futuristic 3D technology that is now becoming a modern necessity in an
mechanical engineering lab. As a member of the mechanical team for
EcoCAR and the Manufacturing Focus group, the HandySCAN 3D would
ease the complex process of reverse engineering parts. I know that I
would use this to model complex parts that would be difficult otherwise
to model.

Lambert, Nickolas

The 3D CAD scanner will give the EcoCAR team an opportunity to focus
their time on design analysis and innovation rather than spending hours
modeling a complex part on the computer. We can then use the scanned CAD model and modify it to any desired specification. The EcoCAR team will be able to see how well a part fits with others before actual application / integration, saving resources and time. Having a 3D scanner will help us create an efficient, exciting car while minimizing problems and defective parts.

Nang, Jonathan

The 3-D scanner will allow the team to be able to model complex parts
such as a engine block that would days-on-end to do. It would allow us
to get all the intricate details and have a potentially much more accurate
model to use. Not to mention 3-D CAD scanning has started being used
much more in industry, and it would allow students on the team to gain
valuable experience getting antiquated with some industry practices
involving 3-D scanning

Kahlon, Savdeep

Having a 3D CAD scanner for UW EcoCAR to use would be great to scan
objects that have difficult curved components. With the ability of this
new feature, we could increase our precision in designs as well as save
time to focus on other projects!

Joanna Mazer

Items

Group Funded Item Unit price Quantity Subtotal
Scanner

Researchers package HandySCAN 700

$51,210.00 2 $102,420.00
Description

The HandySCAN 300 and 700 offer you accurate measurements in real life operating conditions with NO rigid setup required, self-positioning and reliability. It is a lightweight, small scanner allowing you to access easily confined spaces. Generating an STL file in real time, these new scanners offer you a highest measurement rate among all other laser scanners and a quick workflow integration. The new scanners will be your best ally at all stages of your products lifecycle development!

Justification

This item is the necessary hardware component.

software

Vxmodel software

$2,940.00 2 $5,880.00
Description

VXmodel is a post-treatment software that directly integrates into VXelements, Creaform’s 3D software platform, and allows the finalization of 3D scan data to be used directly in any CAD or 3D printing software. Provides the simplest and fastest path from 3D scans to computer-aided design or additive manu-facturing work flow.

Justification

Software package necessary for 3D scanner.

Total requested: $108,300.00

Total funded: $108,300.00

Comments

No comments