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How it Works - continued
Mechanical Design
Mechanical Design is a means by which dimensional information can be combined with concepts to achieve specific goals.
Reverse Austin uses state-of-the-art Computer Aided Design (CAD) software maintained to the latest revisions and updates. We have experience in a broad range of applications including tooling and fixtures for machining, testing and quality control as well as medical devices including orthopedic implants and mechanical heart valves. We've worked with components weighing hundreds of pounds as well as parts weighing only a fraction of a gram.
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Rapid Prototyping
Rapid Prototyping is a means to evaluate designs using physical models produced at minimal cost in minimal time.
Most Rapid Prototyping methods involve additive processes to create physical components based on computer (CAD) models. Unlike machining, where parts are carved from larger pieces of material using machine tools, and unlike casting or molding, where molds are first built by machining and then used to cast or mold components, additive processes, like Stereo Lithography (SLA), Selective Laser Sintering (SLS) and 3D printing, build parts (or molds for parts) directly from powdered materials or liquid plastics. Powdered materials include plastics, ceramics and metals.
Rapid Prototyping starts with a CAD model of a component. The CAD file is first converted to STL format and then loaded onto the computer that controls the Rapid Prototyping equipment, which slices the STL model into parallel layers only a few thousandths of an inch thick. For each layer in the STL model, the equipment deposits a thin layer of powdered or liquid material and then uses a laser to fuse or harden the material before adding the next layer. Once completed, the component is often post-processed to increase its strength or wear resistance by UV curing, sintering or infusion with metals or adhesives. While usually not as strong as conventionally made parts, the components are good for visualization and are often capable of being used for limited physical testing. Continuing advancements in materials enable Rapid Prototyping components to be used in more and more testing scenarios.
No matter how good the engineering, no matter how detailed the computer simulation, a design isn't proven until we can touch it and/or put it in service. In most cases, Rapid Prototyping is the quickest way to get parts that we can touch and, in many cases, it is the most efficient method to get serviceable components for testing.
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Digital Shape Sampling and Processing
Digital Shape Sampling and Processing (DSSP) is a means to leverage dimensional information stored in the everyday items that surround us. See also: Reverse Engineering
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All the physical objects that surround us share one thing in common, they all have shape. Whether a book, a basket ball or a ballet dancer, all things store dimensional information that can be collected and utilized. DSSP is the use of 3D laser scanners and sophisticated software to capture the information stored in shapes and to convert that information into formats useable by a variety of disciplines such as Reverse Engineering, Computer Generated Imaging (CGI), medical device design, art preservation, archeological documentation, etc.
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Rapid Manufacturing
Rapid Manufacturing is a means to produce limited numbers of parts with very little lead time.
Most Rapid Manufacturing methods are similar to or involve Rapid Prototyping methods, the key difference being that, rather than building one or two parts to evaluate a concept, parts are built in larger quantities and are intended for serviceable use. In addition to the additive processes used for Rapid Prototyping, Rapid Manufacturing may involve Computer Aided Manufacturing (CAM) coupled with Computer Numerical Control (CNC) machine tools to create physical components based on computer (CAD) models with little human intervention. Often, alternate materials are used as in the case of Rapid Molding where molds intended for limited use are quickly machined out of aluminum using high speed CNCs as opposed to production molds machined from hardened steel.
Rapid Manufacturing is not intended to replace conventional manufacturing, but rather to provide an intermediate step between Rapid Prototyping and full blown production.
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Legacy Documentation
Legacy Documentation is a means to formally preserve dimensional information associated with existing objects.
Many, if not most, of the objects designed today are designed using Computer Aided Design (CAD) software. For each of these items, there exits a detailed computer record containing all the relevant dimensional information. These records can be used for formal documentation. For objects designed even ten years ago, there are few computer records, often there are no records of any kind. Legacy Documentation is the creation of dimensional records (usually computer records) for existing objects for the purpose of formal documentation.
Why is formal documentation important? Let's say you're the manufacturer of a life critical medical device, like a mechanical heart valve. In one of your manufacturing processes you use a particular tool or fixture. As part of your FDA approval process, you have to be able to prove to the FDA that you have revision control over that tool, that you periodically inspect that fixture and compare the inspection results to the formal record and can tell if the tool is worn or has been modified. Even if you're not in an FDA regulated industry and not making heart valves, if a tool, fixture or piece of equipment is mission critical, you need documentation so you can copy, repair or rebuild.
Legacy Documentation isn't limited to machine parts. Art, antiques, archeological artifacts, coins, custom luxury items (cars, motorcycles, boats, guns, etc.) can benefit from dimensional documentation.
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Reverse Engineering
Reverse Engineering is a means to leverage legacy design information.
We are constantly surrounded by information, some in the form of written or printed material, some displayed on our computer monitors, some transmitted to our TVs and radios, but most is stored in the thousands of physical objects that surround us. Most of the time, we use this information in its "native" format; we read a book, drink from a beverage can, drive a car, etc. But sometimes we extract engineering information; measure books to build a bookcase, measure beverage cans to design a cup holder, measure cars to build garages, etc. The extraction and use of engineering data already stored in physical objects is Reverse Engineering. - using information stored in one object to design and build another object.
Reverse Engineering can also be used to measure objects for the purpose of creating copies. Spare parts can be copied for equipment for which spares are no longer available. Automobile designs sculpted in clay by artists can be copied in metal to build thousands of cars. Sculptures can be copied and the copies put on display to preserve the originals.
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Just as a copy machine can be used to violate copyrights, Reverse Engineering methods and equipment can be used to "plagiarize" engineering efforts. While few would object to measuring beverage cans in order to build a better cup holder, most would condemn measuring someone's cup holder in order to build and sell copies or knockoffs. Inappropriate use of engineering data has given Reverse Engineering a bad name and is a principal reason behind industry efforts to rename it Digital Shape Sampling and Processing (DSSP).
Regardless of the name used, the vast majority of Reverse Engineering is performed for legitimate purposes and provides information critical to the designs of most of the things that surround us. Reverse Austin takes every reasonable precaution to limit the use of its data to legitimate endeavors and does not knowingly participate in condemnable practices.
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Dimensional Verification
Dimensional Verification is a means to assess dimensional conformance of components to design specifications.
A basic Quality Control function is to determine whether or not a manufactured component meets the dimensional criteria specified by the designer. Parts involving only prismatic features (flats, rounds, spheres, etc.) can be inspected using fairly straightforward conventional methods. As design and manufacturing methods advance, more and more non-prismatic features are being used resulting in shapes that must be machined using CNC profiling. Such shapes do not lend themselves to being evaluated using conventional tools and methods.
Complex "surfaced" parts are best inspected using scanning techniques. The most accurate of these techniques uses scanning touch probes that physically trace surfaces in specified locations. While these techniques can be extremely accurate, they are limited in application. The equipment used is typically fixed base equipment; parts must be brought to the machine and the parts must be small enough to physically fit on the machine. Additionally, the scanning head only collects a few thousand points per second and then only along predetermined scan lines. So although the data is very accurate, it is limited in quantity and only represents a small fraction of the part being inspected. While not as accurate, laser scanning collects much more data and can collect it from virtually the entire part. Additionally, portable scanners, like the ZScanner 800 used by Reverse Austin, can be used almost anywhere and on almost any size part.
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Adaptive Machining
Adaptive Machining is a means to increase efficiency by customizing machining operations based on the dimensional properties of the parts being machined.
In traditional machining, most machined parts start as blanks in the form of raw stock (rods, bars, plates, etc), forgings or castings and the machining processes are tailored to remove the excess material. The blanks are usually dimensionally consistent and the machining process is designed to handle minor variations.
Adaptive Machining is beneficial when the dimensional variations of the blanks are large or are unknown. Using a 3D laser scanner, the precise dimensions of each blank are captured and converted to STL or CAD formats. Using advanced 3D comparison software, the converted data is compared to the CAD data for the final desired component to determine exactly how much material is to be removed from each surface. The machining process is then tailored on a blank by blank basis to remove precisely the correct amount of material, eliminating unnecessary roughing cuts and ensuring that all machined surfaces "clean up". Knowing where and how deep to take the "first cut" can be critical to the successful machining of large and/or complex parts.
Adaptive Machining is also beneficial when re-machining repaired components, especially those repaired by welding. Rather than re-machine an entire component, the part can be scanned and the machining process modified to only re-machine the welded area.
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3D Laser Scanning
3D Laser Scanning is a means to quickly capture large amounts of highly accurate dimensional information.
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Reverse Austin uses the latest technology scanner, the ZScanner 800 from Z Corp, to capture your dimensional information on site. The scanner has an accuracy of +/-40µm and captures 25,000 dimensional points per second. Previously, this level of performance was only obtainable using fixed based equipment in a controlled lab like environment. The ZScanner is highly portable and can be calibrated to your environment making it possible to measure your parts at your location.
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Data acquisition using a scanner is only the first step in producing useable information. Most older technology scanners output their data as "point clouds" that require significant post processing to convert into formats useable by most CAD/CAM systems. However, the ZScanner outputs STL format which is directly useable by many systems.
Whether STL format or point clouds, Reverse Austin uses the latest XOR reverse engineering software from RAPIDFORM and the latest Synchronous Technology CAD software from Solid Edge to add the greatest possible value to your projects.
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