The Transformative Impact of 3D Scanning on Industrial Manufacturing

The manufacturing industry has evolved significantly since the Industrial Revolution, evolving from the introduction of machine-based production to the emergence of automated assembly lines and more recent innovations like AI.

In the 21st Century, new technologies continue to be rolled out, rapidly transforming the manufacturing process with greater efficiency and accuracy as they emerge. 3D scanning is fast becoming one of the biggest breakthroughs in this area, and it has already had an impact on industrial manufacturing. It has changed the way manufacturers design, inspect and produce components, and it will continue to shape industry processes for years to come.

What is 3D Scanning, and Why Industrial Manufacturing?

Essentially, 3D scanning describes any process of digitizing a physical entity, right down to its dimensions and finer details, then generating a 3D model. 3D scanning can involve using multiple technologies including laser scanning, structured light scanning, photogrammetry and more to capture an item’s surfaces. This workflow allows objects of any size to be digitized for different applications, ranging from tiny machine parts to huge areas and infrastructure. 3D scanners can be handheld, compact devices that are lightweight and maneuverable.

3D scanned image — 3D scanning captures images that once edited and reverse-engineered can result in a complex digital twin.

3D scanned digital representations of physical objects can be analyzed, modified, tested and reproduced. From product prototyping to manufacturing, 3D scanning cuts the costs and lead times behind object data capture. Highly accurate scans also improve the reliability of processes, while CAD and CAM program compatibility allows for seamless reverse engineering, inspection and quality control.

Among the benefits of industrial 3D scanning:

High accuracy and precision. 3D scanning captures parts and assemblies in high-resolution with sub-millimeter accuracy, allowing manufacturers to reduce errors and ensure that exact tolerances are continually met.
Improving speed and efficiency. The technology reduces manual measurement and inspection times, streamlining workflows and increasing efficiency.
Minimizing costs. Leveraging 3D scanning means eliminating the need for expensive prototyping and physical modeling, saving users time and money.
Bettering product quality. Accurate 3D scans ensure better fit and finish on products.

3D scanning is transformative in applications such as:

Reverse engineering. 3D scanning allows manufacturers to iterate upon existing designs by capturing physical products, fabricating spares with missing documentation or tinkering with legacy parts without needing to take manual measurements.
Prototyping and product design. Precise, high-resolution 3D models can be used to quickly and easily test designs, cutting down the time it takes to get from prototype to production. Using 3D scanning, companies have reported achieving 20 times faster lead times in industrial processes like product packaging.
Quality control and inspection. 3D models can be created in minutes and compared to CAD designs, reducing time-to-market via quality control optimization.
Custom manufacturing and additive manufacturing. Beyond conventional manufacturing techniques, additive manufacturing can bring previously impossible design concepts to life and support the creation of custom-made parts.

The results speak for themselves. For example, a Swiss food-packaging manufacturer cut costs and lead times around packaging for chocolate bunnies from 20 hours to just one, resulting in cost savings. Designing complex wrappers and packaging for Santa and bunny-shaped chocolates in grocery stores every holiday is a challenge.

Bachmann Forming AG does just that; they produce to-spec smart packaging solutions of the highest quality. In the past, this would have required the creation of a master form or pilot tool, and up until 10 years ago, most of the original models were made by hand in a 20-hour-long process. With a handheld 3D scanner, the company is now able to process and analyze both the geometry and color data of a confectionery item and create perfectly fitting packaging in a fraction of the time.

Using 3D scanning, Dodman Ltd has also managed to digitize an entire factory floor in less than a day, and reorganize the machinery models within to achieve cost and efficiency savings. Accurately capturing a pea sorting setup made it possible to survey and plan on a virtual factory floor.

Once edited, the factory mesh was sent to CAD design platform SOLIDWORKS, where it was reverse engineered with the Mesh2Surface add-on, so machinery could be separated, moved, and built around virtually. The result? A complex digital twin of an enhanced production line, which was later used to ensure proper fit and model performance.

Reverse engineering software — Highly accurate 3D scans can improve the reliability of processes, while CAD and CAM program compatibility allows for reverse engineering, inspection and quality control.

The Future of 3D Scanning in Manufacturing

3D scanning has transformed industrial manufacturing by improving process reliability, cost efficiency and lead times. As the technology behind 3D scanning continues to advance, its manufacturing applications will only multiply, mature and drive innovation. Those who integrate 3D scanning into existing processes are positioning themselves to thrive in the next era of manufacturing.

Looking ahead, the integration of artificial intelligence (AI) will enhance 3D scanning’s capabilities further, enabling real-time data collection and predictive maintenance. As Industry 4.0 advances, 3D scanning will also become an essential tool for smart factories, reshaping the industrial landscape by driving ever-greater efficiency and providing new solutions to manufacturing bottlenecks.

By embracing these advances, manufacturers can stay ahead of the competition, harness the full potential of 3D scanning and maximize their return on investment.