Eifel

Eifel and its customers focus intently on what the auto industry calls Class A surfaces—the surfaces that can be easily seen in dealer showrooms. In the hypercompetitive auto business, styling is everything. Net-shape machining uses high-precision machine tools and computer numerical controls (CNCs) to cut metal precisely to the math model, i.e., the computer-aided design (CAD) data that defines the part, meaning that hand-polishing or “benching” has been nearly eliminated.
 
"What has changed in moldmaking is that Class A surfaces are now measurable. This meant that the moldmaker could inspect to specifications, making net-shape machining a practical solution for mold manufacturing," stated Hecker. For Eifel, this added up to opportunity. His response was to broaden the company’s services into design and engineering, narrow its focus to primarily airbags and steering wheels, and build high-density point-cloud inspection techniques into every aspect of day-to-day operations.
 
Inspection with scanning ties all this together at Eifel.

3D Scan IT’s solution for Eifel

White-light scanning and point-cloud-based inspection reinforce Hecker’s SPDM business strategy at every decision point. They provide the data on which Eifel engineers and their customers base critical tooling decisions. "Each process verification step speeds up the moldmaking process and makes it more reliable. Addressing any issues up front, before parts are made, ensures that you’re not chasing your tail," Bob Squier, President of 3D Scan IT.  

InnovMetric’s solution for 3D Scan IT

In a minute or less, scanning paints the inspected surface with millions of 3D points. “For us, PolyWorks converts all of the overlapping scan data into a single skin polygonal model,” said Squier. “In just minutes, the 3D point data is reduced by 95% or more to a manageable file size. That polygonal model is then inspected to the math model from the customers’ CAD system.”

Millions of points to evaluate the quality of molds

Data was collected using the Imetric IScan V, White Light Digitizing System. The scanning system was calibrated for the 150 mm volume, which give a point resolution/spacing of 0.080 mm. This is more than 150 points per square millimeter.

The IScan V scanner works like a 3D camera. For each pixel in the camera, a 3D coordinate is calculated. Therefore, for each 3D picture or scan, 1.3 million points can be measured. Since all features of the part cannot be seen from any single vantage point, multiple scans are collected and aligned using common navigation points.

Point-cloud-based inspection in PolyWorks

After performing a 100% object scan, the data was then merged into a polygonal model. The IMMerge functionality allows for dramatic point cloud size reduction for smoother and faster inspection times. This polygonal model was then inspected to the provided CAD model via IGES. A best-fit alignment technique was used in conjunction with the parts datum alignment scheme. With the added versatility of the macro functionality, an interactive inspection macro was performed on all parts to ensure repeatability of inspection process and to increase speed.

This inspection macro preformed the following inspection elements: Best-fit Alignment, Comparison to Reference, Snap Shot Report Images (taken from predefined perspectives), GD&T elements (inspected with all relevant datum alignments being performed), Comparison Points (for a discrete point, for CMM-style inspection result), and Boundary & Edge points (using the Error Annotation functions). All results were reported in PolyWorks EZLayout report tool.
 
The inspection macro automatically inserted all of the reported inspection elements into a standardized inspection report layout using the EZLayout tool. This report was then printed, and distributed for review as a PDF file.