For centuries, processes for producing certain tools were kept relatively similar. At the industrial revolution, the property of a few and knowledge of a few others allowed us to automate these procedures and refine them.
Now, with services like Shapeway's 3D printing, the computer age has given the tools for anyone interested to become privy and capable of manufacturing anything we can think of, and design using CAD software. But, these capabilities are being expanded, generalized, and becoming even more accessible as software becomes the main platform for designing and we let CNC machines do all the work. Perhaps the best example of our complete domination of the manufacturing process is what the 3D Systems subsidiary, Rapidform, has done to turn any physical object into a CAD drawing that can be virtually modified or physically brought back to life.
The Rapidform process is primarily used for reverse engineering of any object. Since modern manufacturing is heavily reliant on CAD suites to design and test, many objects that were created before the advent of CAD technology were disregarded, or needed to be painstakingly measured and redrawn in software. Procedures that take up a lot of time that risk losing accuracy and information of an original archaic-component are unacceptable tradeoffs to successful modern manufacturing. This could be a huge problem for people trying to restore a 1920s vehicle, whose parts have been long discontinued and are hard to find. Jay Leno can attest to this -- he used Rapidform to reverse engineer obsolete parts for his Big Dog Garage.
Rapidform's solutions take several 3D scans of the broken, fatigued, or discontinued piece. Precisely combine these scans and then redraw it, using computerized tracing software. This drawing could then be exported to a familiar CAD package used by industry manufacturers to rebuild the part. This, in short, is what the Rapidform software does.
Rapidform has divided its software into three different sections, XOS, XOR, and XOV, and all three are vital for the accurate reverse engineering of parts. The XOS software allows users to convert the data from any 3D scan into a highly accurate mesh or NURBS surface. It also facilitates combining and aligning multiple scans, and gives choice of producing meshes with adequate amount of resolution including defect-free meshes. The XOV program is used at the end as it automates the verification of tolerances by comparing the traced parametric drawing with the data obtained from the scans.
In order to create the drawing, the scanning data is used within the XOR software to perform the digital tracing. As any CAD user knows, creating slanted surfaces or curved features at irregular angles is difficult and could take hours. Performing this tracing is exactly what is unique to the XOR program.
The XOR developers have developed simple functions that use as much of the scan data as possible to create the CAD rendering. This software is capable of detecting and color-coding all the different features of a scanned part automatically. Specialized tools like the Lofting Wizard allows the program to detect angled and curved surfaces automatically. It snap-fits general, idealized curves to the scan, and the user must simply edit them in order to achieve a fit within tolerances. Pattern tools can finish repetitive work and make editing fast, just as in regular CAD and fillets, plus other finishing tools allow the user to complete drawings, to precise specifications, on the XOR program itself.
Cabe--Great article. I have spent hour upon hour measuring dimensions from actual part configurations to produce drawings. Early in my career, I was a team member given the task of reproducing drawings after a fire that destroyed much of the data base for many of the products manufactured by our company. Back in those days everything was "paper", no CAD, etc etc. We, of course, did have copies but many of those were unreliable for various reasons. This project took the better part of six months and was a painstaking process. I will say one thing, as a "rookie" engineer, I certainly did get the feel for the products we were manufacturing and that greatly aided my efforts in understanding design processes and reasons for certain features. We certainly could have used the software from Rapidform 3D at that time.
I wonder if there will be some fuss made about the ability to copy things without having to design them. Right now we have all kinds of inconveniences and limitations because of the crybabies. We have digital rights management code deciding if we can make a copy to keep in the car, or transfer to a different media, or make our own collection of music. Likewise with DVDs. And you just can't play a CD from other parts of the world, no matter how legal it is.
So just imagine the howels when somebody produces a copy of some overpriced item. We will have an interesting situation indeed. Imagine a "duplicate" Rolex watch, if you will. Of course, the quality may be really hard to copy, but not the image and appearance. At least that is how it looks to me. And just imagine what it would be like if somebody could copy some of the more serious military weapons. Grab one and scan it and then print out and asemble dozens.
So digital bootleging may inspire some sort of regulations, but I can't imagine how they would work.
The D-Shape is definitely art-oriented, and also architecture oriented. If you look at the stuff the inventor has done with it, like fancy, swirly shaped architectural elements, I think it would be the perfect candidate for our cave art wall.
Herzog is definitely a nut, but a creative, innovative one. I'd forgotten the crack about crocodiles--that was weird. If you mean the D-Shape 3D printer or others of its type, like I wrote about in a recent Future Cities blog http://www.ubmfuturecities.com/author.asp?section_id=262&doc_id=523906 they don't actually print stone, but some of its constituent materials: e.g., sand, gravel, or clay, using a binder. But that said, whatever came out of it would look like the real thing.
With the recent development of the 3D rock printer, rear stone could be used. That is a wild idea.
Herzog did say some weird things in that film. Like, "Are we today, possibly, the crocodiles who look back into an abyss of time?"
On that note, he eluded to the fact that the crocodiles were a post idea to the film. And possibly not really related to the area where the film was shot. It's entertaining though...
That was one of my favorite Herzog movies, and one of the few I've ever wanted to see in 3D (although we didn't get to). He is an odd duck, but definitely a genius--who else would have thought to make that movie? Having part of Altamira, Lascaux or Chauvet in one's living room would be an amazing experience.
I look forward to the maturation of 3D scanning. I hope it becomes accessible, like 3D printing, to the masses. I'm sure we will see countless bootlegging of products, but that the way the world works. It may force companies to create better products, beyond the quality of household printing.
I foresee someone taking the 3D scanned caves and building the places into their homes. Imagine if part of our homes were an accurate recreation of Werner Herzog's "Cave of Forgotten Dreams."
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