27 years of Unusual Laser Scanning Projects
 GKS’s veteran metrologists have performed many unusual scans in their careers. Some that have come to the fore in the recent years are big, really big—large-scale in fact. They have ranged from huge oil drilling platforms in the ocean to an entire prison compound, decommissioned of course. Laser scanning projects and customers have grown exponentially in size and number since the technology’s inception in the mid-1980s.
Steve DeRemer, GKS General Manager, Michigan Region, and Larry Carlberg, GKS Service Bureau Manager, Minnesota Region, share a few of their favorite, unusual projects:
Engine Supercharger
Although this scan was not done with a long-range laser scanner, it was still an unusual and complex one. “We see a lot of engine parts and turbines, but not too many superchargers,” commented DeRemer. This customer was designing an improved performance aftermarket supercharger from the external casting of an old OEM stock supercharger for which there was no CAD model. The supercharger had very complex shapes, free-form curves, and radii that were critical to its high performance. These features would be hard and time-consuming to duplicate with a CMM. Non-contact 3D laser scanning the casting gave the customer a quick CAD model to which the design modifications, and changes could easily be applied.
GKS metrologists laser scanned the complicated supercharger casting quickly in only 3 hours. Over 2.5 million points were collected in the point cloud data. Conventional measuring would have taken much longer, up to 20 times longer, and the data would not have been as accurate and complete. Once the scanning was done, general clean up and post-processing the data into an STL file took approximately 4 hours.
The customer then used the STL to build his own CAD model which he modified to develop the new improved casting molds. Having a real dataset of the supercharger profile instead of having to work from hand drawings vastly improved the redesign process. The customer was “thrilled” with the detail and accuracy of the model generated from 3D laser scanning.
Who cares: Industrial product designers and engineers who need to update and redesign products that have no existing CAD data.
Dung Beetle Horns
When using the old adage “size matters,” who would have thought it applied to dung beetles! An entomologist who was seeking a method for accurately calculating the volumes of the tiny horns of dung beetles, contacted GKS for an estimate. The horns range in size from ½ mm to 15 mm. Eventually the scientist wanted to scan over 50 dung beetle horns to determine how much energy goes into producing them, presumably improving that beetle’s chances of passing on his DNA.
GKS laser scanned several specimens of dung beetle horns and edited the data to make sure it was complete and clean. A theoretical border was then provided, so the scientist could consistently calculate volume from the same reference plane.
The customer was amazed at the minute details captured with the ultra-precise Laser Design laser probe and the ease in calculating the horn volumes with the specialized scanning software. Since the dung beetle horns are so tiny and the shapes are irregular, accurate and consistent manual measurements would have been extremely difficult and labor intensive to obtain. GKS was able to provide excellent results for this study quickly and easily.
Who cares: Anyone dealing with recreating or measuring very minute objects (scientists, jewelers, toy makers) and need digital models.
Eroding Sand Dunes
Long-range scanning has been used quite frequently in measuring natural features and landscapes in the construction industry. “We are just beginning to appreciate its uses in documenting land formations,” noted DeRemer.
GKS was called upon to scan sand dunes in order to document their erosion due to human-made and natural causes such as foot traffic, wind, and rain. Land-use specialists want to find out how much erosion occurs due to compaction of the sand where people walk and if pathways are detrimental to the naturally evolving environment.
Documenting the changes at regular intervals over time will provide data upon which to base future decisions about how the area is used for recreational purposes and how to best preserve the natural elements.
Since sand is fairly featureless, distinct geographic reference points were use as markers to make sure the scans were measuring the same areas correctly. The erosion process was clearly visible in the regular series of scans.
Who cares: Ecologists and those charged with protecting natural environments, including parks that have preservation and land-use issues.
Ships’ Tanks
A couple of projects that GKS performed on ships’ tanks had different purposes: one was to determine the exact volumetric capacity of oil tanks; another was to use scan data along with CFD (Computational Fluid Dynamics) to solve a problem with ballast tanks not taking on water as designed. GKS engineers encountered the same scanning conditions in both scenarios, that is, access to the scan area was limited and the inside of the tanks was dark. Luckily, long-range laser scanners are quite small and portable, and they can function in all kinds of adverse conditions, such as cramped spaces and in the dark. Both scans were performed without a hitch.
Capacity of Oil Tanks on a Tanker Ship
Until now the only way owners of oil tankers knew how much oil they held was by taking the word of the company that constructed the ship. There has not been a good way to measure volume after the fact. Even the shipbuilders were not certain whether the tanks had been calibrated very precisely. Who can tell for sure how much a huge tank is off from the given spec in number of barrels?
The owner of one such tanker decided to find out the exact volumetric measurement of his tanker’s storage tanks as a quality check. He calculated that if the stated amounts were off even by a few hundred barrels, his company could be losing thousands of dollars with every transport trip.
GKS was hired to scan the inside of the tanks and precisely determine their capacity. Access to the scan area was limited and of course, it was dark inside the tanks. As usual, the portable long-range laser scanners functioned perfectly and the scanning process successfully recreated the tanks so the volumes could be accurately calculated. The owner then had certifiable evidence of how much oil he was transporting. This generated confidence in his ships’ traceability with his customers, a huge advantage to the oil transport business.
Ballast Tank Problem
A military ship was having difficulty controlling the water intake of its ballast tanks. For some unknown reason, the tanks were not taking on water as they should have. This was adversely effecting the ship’s fuel consumption and hydrodynamics. The commanders contacted GKS to scan the inside of the ballast tanks, both to measure their volume, and to ferret out a reason why they were not performing as designed. Using the scan data collected by GKS, Computational Fluid Dynamics (CFD) software would be applied to analyze water flow problems, leading to improved tank and structure architecture, fuel efficiency, power transfer, craft stability, and safety.
Although conditions were challenging in the huge, dark tanks, the long-range scanner was able to perform the scan as ordered since it does not need light, nor access for bulky measurement tools in order to function flawlessly. GKS engineers were able to scan the tanks’ interiors and determine wear differences on the inside walls, indicating where water levels were irregular.
It turned out that the tanks were not filling to capacity because the interior shape was creating very large air bubbles as the water flowed in, preventing them from providing the ballast the ship needed to perform optimally. The wall surfaces were pitted unevenly and water lines were evident in the scan data which can detect minute unevenness of only a millimeter or two. The CFD analysis then showed what was wrong with the tanks’ internal surfaces. With this knowledge, the tanks were redesigned with better hydrodynamic shapes to correct the water inflow. Better hydrodynamics translated into better fuel efficiency and cost savings
Who cares: Marine engineers, naval architects, shipbuilders, and owners concerned with storage and ballast tanks, and/or engine efficiency, fuel consumption, hull hydrodynamics, and other environmental upgrades.
The Interior of a Water Tank at an Aquarium
DeRemer receives some requests that might be considered a bit oddball for the uninitiated. He, however, carefully considers the unconventional project before making a determination of whether GKS can accommodate the customer. An aquarium contacted GKS to see if they could scan one of their installation tanks full of water to capture the geometry of the aquarium features and the fish swimming around. Unfortunately, this particular scan was not physically possible.
Although laser scanning easily captures free-form shapes, they must be stationary in order to do so. “I don’t think the fish and sea creatures would have held a pose while we scanned them,” DeRemer quipped. “Although our high-speed lasers capture tens of thousands of points per second, it is not an instantaneous process to capture a large area like an aquarium tank!” Another contraindication is that water is both reflective and translucent, two qualities that are difficult to scan even when not in constant flux.
Who cares: Oceanographers and aquarium personnel, please don’t ask about water or underwater items, but we can scan any undersea object when it is on dry land (and not moving).
Offshore Oil Platform
In a project that encompassed not only the large-scale scope of a multi-faceted industrial complex, but also harsh ocean-based conditions, GKS was called upon to scan an offshore oil platform to document its structure and modifications over time. Incomplete or obsolete offshore facility documentation plagues offshore engineers who are tasked with constructing, modifying, and updating the platforms. The hazardous surroundings demand extremely efficient and safe working procedures, so accurate 3D models are essential.
GKS engineers have scanned many offshore refineries and rigs with their long-range scanners, providing valid as-built data and models. Long-range laser scanning systems are portable and quick to set up, so scanning can be performed in environments where health and safety issues are paramount.
Offshore platforms are oftentimes constructed of modules built on land and then assembled on-site. In this type of modular construction, each section must fit together correctly and securely. Tolerances must be closely managed between topside structures and underwater ones to minimize the dangers of underwater construction. With 3D long-range laser scan data completely documenting the as-built condition, building modifications, upgrades, add-ons, or reconstruction of the assembly can now be accomplished with a great degree of confidence. This greatly speeds up the project and, most importantly, provides greater reliability that the project will be completed correctly with no surprises when materials and prefabricated components arrive on the job site.
The offshore construction process itself can also be facilitated by scanning, using the scans to inspect the work at various intervals. That insures that plans are accurately executed and uncovers design flaws before they become costly and time consuming. Long-range scanning is invaluable in conditions that are less than optimal for manual measurements such as can occur on huge oil rigs.
Offshore oil production facilities provide tremendous dimensional control challenges throughput their entire lifecycle. Frequent modifications in the design can be viewed clearly with long-range scan data to check for potential collisions and necessary reworks. This reduces the time required during the construction and can lead to huge benefits. The lifecycle of a facility can be documented through repeat scans detailing any changes occurring while maintaining an accurate record of the current condition.
Laser scanning can validate the entire jobsite geometry including locating tie-ins and anchor bolt locations; it can verify footing dimensions and positions. The technology can also be used to provide measurements on land prior to subsea installation which will, when combined with acoustically acquired position data about the installation point, eliminate the need for much deepwater measurement while providing an accurate first-time fit. In the case of damage from a storm, the structure must be rapidly documented to aid in repair or decommissioning.
In addition the large structural elements, oil platforms and rigs contain mazes of pipe work. Documenting existing setups and planning for alterations can be facilitated by accurate 3D data gathered by GKS through long-range 3D laser scanning. Long-range scanning provides a fast and relatively inexpensive method to produce accurate drawings which are often required in order to comply with the latest OSHA safety regulations.
Who cares: Offshore & marine engineers and naval architects who are responsible for the design, construction, maintenance, and upgrades for large offshore structures including their performance and safety.
Water Wave and Ocean Floor
Carlberg is sometimes amazed at the creativity of potential customers in dreaming up unique scanning projects such as scanning a wave of water or the ocean floor. Unfortunately, these particular scans were not physically possible.
Although laser scanning easily captures free-form shapes, they must be stationary in order to do so. “We can’t scan waves of water because they are in constant motion,” Carlberg explained. Another contraindication is that water is both reflective AND translucent, two qualities that are difficult to scan even when not in constant flux.
The same principles apply in the ocean floor scan. Obviously, it is covered with moving water, so the same issues that prevent scanning a wave are also in force in trying to scan something under water. Both watery scans went down with cement overshoes.
Who cares: Oceanographers and divers, please don’t ask about water or underwater items, but we can scan any undersea object when it is on dry land.
Corroded Pipes
A water research laboratory at a major university was using Computational Fluid Dynamics (CFD) to study water flow in corroded pipes. CFD uses mathematical formulas to analyze and solve fluid flow problems. The lab wanted to determine how much corrosion interferes with the water flow significantly and use the information as a diagnostic to find trouble spots in water distribution systems.
To obtain some baseline readings, the laboratory sent GKS two metal pipes, one 2’ long by 1” diameter and one 4’ long by 2” diameter, cut in half lengthwise, for laser scanning. Each pipe was cut in two to create two half round pieces exposing internal features with a nominal diameter to .002”. The corroded interior surfaces of the metal pipes had become calcified from years of use.
 The four pipe parts were laser scanned to capture all internal and external surfaces, and then digitally merged into closed 3D models. Once more, the non-contact laser probe was able to capture all the pipe geometry, including corrosion and calcification, without damaging the breakable imperfections. The point cloud data were converted into very accurate and complete STL models, which provided the water lab with the interior profiles of the corrosion upon which to run their CFD tests.
CFD will be able to show what happens to water flow when pipes are corroded, i.e., how much resistance it encounters, to predict pipe problems when flow is reduced in real water distribution systems. As this type of research into water flow proliferates, it may some day save you from shivering in a pressure-reduced cold shower. Brrrr.
Who cares: Public works, product designers, R&D departments, research universities
Artwork - From Small to Humongous
Carlberg can tick off many unique scanning projects that involved digitizing pieces of art or models to be enlarged for various unique reasons:
Jack in the Bean Stalk Sculpture
Once upon a time, a model (approximately one cubic foot in size) of a scene from the fairy tale, Jack and the Beanstalk was scanned and reverse engineered on a much larger scale. The enlarged scene was going to be built on the façade of a commercial building to entice customers to enter and see what was inside.
The pieces of the model, such as Jack, the beanstalk, the goose, et al., were scanned separately and then reassembled in the CAD model. The most difficult parts to scan were the curves of the beanstalk since they were irregular free-form shapes with very detailed leaves. Several setups were needed to scan the whole scene, but the entire procedure took only a few hours. The point cloud files were systematically converted to NURBS to create the large-scale model from which the scenario was built.
The customer was very happy with the accuracy and detail which made the display very attractive and realistic. And of course, the pieces assembled easily since the scan dimensions of each piece are so accurate and fit together perfectly.
Big Iguana to Gigantic Iguana
A resort hotel wanted to create a one-of-a-kind experience for its guests by building a giant iguana bridge out of lava rock from a nearby active volcano. In order to make the creature lifelike and to a huge scale, they started with a detailed clay model from a fine artist. The model was 44” long, so it was quite heavy and needed a stable base, or it would become misshapen as it was moved around.
Since laser scanning is non-contact, it was the preferred method to digitize the pliable sculpture without marring it or missing its amazing details. The lizardlike sculpture was longer than the scanning envelope and required several positionings of the laser scanner. Data from no fewer than seven scanning positions were all registered together to form the perfect replica of the iguana in digital format. Over forty cross sections were generated to represent the dimensions at each half-meter increment.
Eventually the iguana was to be built as a 300’ long sculpture completely out of volcanic rock. The sheer size and volume of the project dictated that GPS positioning systems be used to stay true to the iguana’s original design intent and keep it in the correct location on a narrow peninsula.
Small Fine Art Sculpture
Sometimes commercial artwork needs to be bigger, but not that much bigger. GKS scanned a 5” fine art sculpted “figurine,” and sized it up to 36” to mass produce. The organic shapes and free-form curves made it impossible to measure and digitize in any other way but non-contact laser scanning. The scanning took only 1 hour on the small figurine, and the post-processing work took another 2 hours.
The true capabilities of the laser to scan accurately, completely, and quickly are showcased with these types of fine art applications. No matter what the customer’s reason, small items can be made larger to scale or large items can be scaled down. Either way, laser scanning creates a perfect digital replica of the piece.
Who cares: Artists, artisans, companies that mass-produce objects, theme parks that enlarge popular characters for architectural elements and display purposes
Dinosaur and Fossilized Teeth
Dinosaur and fossilized teeth are more common than you would imagine. GKS has scanned hundreds of them, and several research universities have purchased Laser Design Surveyor 3D laser scanning systems so they can scan their own inventory of fossils, many of which are teeth.
What all dinosaur teeth have in common (and for that matter any type of tooth) is the free-form shape and non-uniform structure. T-Rex teeth are larger than the teeth of most of today’s animals, about 4” long x 1½” thick, but like other carnivores their teeth have serrated edges. These types of details make measuring with contact methods difficult if not impossible.
Non-contact high-speed laser scanning captures the entire irregular surface of an artifact, such as a dinosaur tooth, in seconds with high accuracy. Small details and the individual serrations are no problem to capture. Minutes later a complete digital point cloud of the scan data is visible on-screen to be modeled and manipulated as needed. The models are accurate to .002” and show incredible detail.
Fossil scan data are often stored in digital databases for archaeologists, paleontologists, and other researchers. The models can be accessed online and easily manipulated in 3D space. All dimensions are instantaneously available for comparison, contrast, and further study. With the ever-increasing cost of travel, this application of laser scanning benefits money-strapped researchers and fossil aficionados alike by being able to access thousands of records from their own computers.
Researchers can determine from the shape and wear of the tooth what animals ate, how they lived, and many other research questions. The futuristic technology of laser scanning gives us a detailed and accurate look into our deep past.
Who cares: Anyone with archaeological items, research companies and universities
Morel Mushroom
Sometimes GKS has been asked to scan certain items just to see if it could be done. Organic items are especially challenging (bones, teeth, leaves, etc.) and in this case, a doozey of an organic item was chosen for the challenge: a morel mushroom. The customer was an avid mushroom hunter and a materials development engineer at Stratasys, a company that manufactures rapid prototyping and direct digital manufacturing systems. His idea was to laser scan the morel, then recreate the complex, convoluted shape with a Stratasys FDM (Fused Deposition Modeling) rapid prototype system directly from 3D CAD files. “Shapes found in nature are unique. There is no way to replicate them via conventional CNC machining-based manufacturing processes,” the engineer reflected.
Laser Design’s Surveyor line of automated and portable 3D laser scanning systems are ideal for applications involving reverse engineering of complex-shaped objects be they metal, plastic, or, in this case, organic. Mainly, the idea was to scan and build a very complex-shaped object, and show the amazing capabilities of 3D laser scanning plus rapid prototyping when they are combined.
Even though the project’s goal, a lifelike replica of a morel, was daunting, the expert metrologists at GKS rose to the task. First, they stabilized the flexible shape of the mushroom by inserting a metal rod into the center. This did not affect the geometry on the outside, but prevented the morel from distorting from the pull of gravity. They then mounted it on a rotary stage to capture as much geometry as possible all the way around from several angles. To recreate an accurate model, the engineer needed high-resolution, high-detail, high-density STL files.
The GKS metrologists knew that the deep inside pockets of the morel would be challenging to scan. The laser scanning system projects a line of laser light onto surfaces while cameras continuously triangulate the changing distance and profile of the laser line as it sweeps along, capturing tens of thousands of coordinates per second that it “sees” with the cameras. However, the surfaces deep inside the ridges and pockets are difficult, if not impossible, for it to see and gather data for.
Because the surface of the morel was so complex and pocketed, the very large data files still contained over 5000 holes in the surface geometry after all the scan angles were performed. The Stratasys FDM rapid prototyping system would not be able to recreate the model using data containing holes. To fill in the missing sections of data manually would have taken many long hours of massaging the data.
Instead GKS decided to use the Rapidform XOR software black box module to automate the process. The software took the huge point cloud of data and automatically fixed and filled the holes in the STL file that was auto-generated from the 3D scan data. It created a continuous surface in a closed STL file which is essential for the FDM rapid prototyping machine to be able to build the part. This data processing step insured the success of reproducing the complex shape of the morel.
From start to finish, the scanning process took about 25 minutes total; 10 for performing the multiple scans and 15 for cleaning up the data with RapidForm XOR software. Stratasys used the files to create multiple copies of the completely lifelike morel in a translucent polymer. “Scanning things in nature is an interesting idea,” commented the engineer. “Laser scanning is a quick and painless way to gather the complex and detailed data to create the natural shapes accurately and quickly. This process would allow mass customization in a limited numbers of lots. Anything, no matter how geometrically complex, can be recreated. The potential for such a process is unlimited.”
Yes, Virginia, we can scan (and rapid prototype) a morel mushroom.
Who cares: Product designers, anyone who needs to model very complex or natural, organic objects for business or pleasure
Shake Painter Prototype Product Design Process
Inspiration for a new invention comes in many guises. A man who sold painting supplies wanted to design a painting tool that would allow easy paint coverage on shake shingles. He had devised a crude mock-up of such a tool with a foam pad and handle. He needed a CAD model to make refinements before mass production, and of course, to use in the fabrication process itself.
The shake painter prototype was about 10” wide and took less than an hour to scan. The non-contact nature of laser scanning was again key in being able to produce an accurate digital model without compressing the foam surface.
Once the scan data was post-processed, the inventor made stylistic modifications in the handle to make it more ergonomic. The design went on to be a best-seller and the basis for a successful multi-million dollar company.
Who cares: Product designers, inventors, prototype makers who need digital models
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About Laser Design / GKS Inspection Services
Laser Design, Inc., and GKS Inspection Services have been leading providers of 3D laser scanning, dimensional inspection, long-range scanning, and CT scanning systems and services for over 25 years, and offer complete contract manufacturing services including product design and rapid manufacturing. GKS also offers rental equipment and expertise to customers with the occasional 3D scanning project.
For more information, call 1-888-457-7727 or request a quote.
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