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3D Technology in automotive industry

Recently, one of our partners, Terem3D reached out, suggesting a project: use 3D technologies to reverse engineer a hard-to-replace car part.

The company wanted to reconstruct a sub-flap bar after a car accident with the help of Drake 3D scanner and reproduce it on the BigRep 3D printer. The bar was relatively small (45 x 5 cm), had a curvature along all axes and had a broken lug. It would be difficult to measure it using conventional tools, so the Drake scanner was used.

The step by step:

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Img. 1-3. The metal car part brought in for scanning.

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The job itself took a few minutes. We added some crumpled paper around the object to add “geometry” and help with for tracking during scanning.

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Img. 4. 3D scanning with Drake 3D scanner.

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Img. 5. Paper was added around the object to create extra geometry to improve tracking.

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Img. 6. The scan of the broken bar. The chip is clearly seen.

After scanning was done, Terem3D post-processed the scans in the Netfabb software. At this stage the broken lug was repaired.

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Img. 7. Post-processing. The lug was repaired by hand in Netfabb CAD software.

After post-processing, the bar was successfully printed on the BigRep 3D printer ready to be used:

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Img. 8. New sub-flap bars printed by 3D printer.

The car was ready to go!