CROSS-SECTIONAL SCANNING

MANAGING MEASUREMENT UNCERTAINTY.

In metrology, both measurement uncertainty and the resulting potential for error are always present. Regardless of the technology employed, there can be an accumulation of tolerance errors in each element of the measurement process, putting the reliability of the inspected dimension in doubt. According to NIST (National Institute of Standards and Technology), a quantitative statement of the measurement uncertainty should accompany all inspection data. Therefore, it is critical to manage uncertainty and to understand that the sources of error go beyond just the measurement.

Minimizing and managing uncertainty requires a comprehensive view of the instrument, operator, part, methods and environment. Collectively, these elements contribute to errors in inspection. While controlling the variation of each of these influencers will reduce the error and make it more predictable, the best practice is to eliminate the influences altogether. Cross-Sectional Scanning does just that.

Cross-Sectional Scanning's published error range is 0.0008 in. (20M). Unlike the repor ted accuracy of CMMs and other 3D scanning technologies, this statement encompasses not only the metrology instrument variance, but also every other element of the inspection process. Consequently, using Cross-Sectional Scanning for first article inspection, tooling verification or ongoing process control will yield inspection reports with a relatively higher degree of certainty.

Consider the uncertainty factors associated with other technologies. When inspecting with a CMM, variance is introduced by the machine, by the methods, and by the operator. Even the design of a fixture, placement of the fixture, or mounting of the part can introduce unwanted error. With 3D scanning technology, the potential for variance comes from the scanning hardware and from the processing of the point cloud. Alignment of scans, elimination of noise, and operator-influenced processes will yield varying results for the same part.

Cross-Sectional Scanning minimizes uncertainty in measurement.

Cross-Sectional Scanning is different, unique. The operator is removed from the uncertainty equation, fixtures are eliminated, scan alignment is unnecessary, and noise is nonexistent. These factors, and others, make Cross-Sectional Scanning repeatable, reproducible and reliable. Uncertainty is minimized and confidence in measurement accuracy is maximized.

Applications:

• First article inspection
• Failure analysis
• Process qualification
• Reverse engineering

Advantages:

• Greater certainty
• Greater accuracy

PINPOINT THE TRUE CAUSE OF FAILURE.
Despite injection molders' best efforts, quality problems will arise and parts will fail to meet specifications (spec.). The failure may be due to an oversight in first article inspection, worn or aging tooling, or a change in molding suppliers. To fix these problems, companies need to determine the true root causes. With Cross-Sectional Scanning, companies can easily pinpoint the problem, detect the root cause, and make the necessary repair.

Conventional inspection technologies provide only part of the picture. Without complete information, it may be impossible to determine the cause and effect. This can lead to costly, time consuming conclusions that do not address the real problem. Cross-Sectional Scanning is different; it produces inspection data that completely describes the part. With the ability to scan most complex molded parts, this technology lets you see all features, both inside and outside.

An ultra-dense point cloud is the basis for a powerful visual tool that directs your attention to potential trouble spots. Color mapping produces a 3D image of a part and highlights out-ofspec. features in reds, oranges, cyans and blues. Focusing analysis on what is out of spec. eliminates the investment of time in inspecting what is in spec. This expedites the process, provides an accurate picture of the problem, and lets companies respond with a correct solution.

In seconds, color mapping shows deviation from either the original design data or archived data from first article inspection. Because Cross-Sectional Scanning captures internal and external features, the color map can be crosssectioned to highlight faults within a part. Identifying the real problem eliminates assumptions and lets you determine the root cause.

One company reports that a CMM inspection of a precise molded part lead to an erroneous conclusion that the injection mold needed to be rebuilt. Luckily, this company opted to use Cross-Sectional Scanning to inspect the problematic assembly. The color map function clearly indicated that there was no problem with the mold; instead the problem was with the molding process settings. A simple process change, rather than a new tool saved this company $75,000 and avoided a two month delay in product launch.

Manufacturing is rife with variables, some controllable and others unpredictable. These variables will yield parts that fail inspection. Instead of diagnosing the problem with incomplete and inaccurate information, apply Cross-Sectional Scanning and color mapping to detect the root cause and to determine the best plan for repair.

Application:

• Failure analysis

Advantages:

• 100% inspection
• Color mapping
• Highlight problems
• Determine best solution

CROSS-SECTIONAL SCANNING DELIVERS 100% INSPECTION FOR THOROUGH ASSESSMENT OF COMPLEX MOLDED PARTS.

Traditional inspection tools may yield an incomplete assessment of injection molded parts, and with a direct correlation of time to measurement points, more data may be impractical or impossible. As the demand for quality heightens, time to market shortens, and designs become increasingly complex, new tools are needed to maintain a competitive advantage and to reduce product costs.

Cross-Sectional Scanning from CGI Inspections is one such tool for these dilemmas. This optical inspection technology creates an ultra-dense point cloud that delivers 100% inspection and data capture. Every feature—whether internal or external—is fully described.

Cross-Sectional Scanning is used for inspection and reverse engineering of components that are intricate, featureladen or complex; it is also used for parts that have inaccessible features. It can handle most molded materials, including clear plastic. With automated operation, job templates and advanced color mapping, Cross-Sectional Scanning does more in less time.

To tackle that next project, CGI offers systems, services and software. Choose from the CSS300, CSS1000 or CSS3000 for in-house inspection and reverse engineering. CGI also offers Spec.Check and advance inspections software applications that enable the assessment of part quality days or years after point cloud generation.

How is Cross-Sectional Scanning capable of all of this? It is analogous to rapid prototyping, but in reverse, meaning that Cross-Sectional Scanning is insensitive to complexity. This allows it to capture every feature, replicate sharp corners and run unattended.

Applicatons:

• First article inspection
• Failure analysis
• Reverse engineering
• Process qualification

Advantages:

• 100% inspection
• Color mapping
• Complexity independent
• Internal/external features
• Unattended operation