Employing fifty skilled personnel across two factories in Cambridgeshire, ACE Technology designs and manufactures products, such as pattern & mould tools, jigs & fixtures, etc. These capabilities are complemented by four autoclaves and a focus on quality control processes to drive excellence during composites production. The company has maintained and developed client relationships across several sectors, with the implementation of advanced metrology becoming a fundamental part of its business.
Combined with this was a desire to offer customers additional services, particularly in the early stages of a design project. This often involves 3D laser scanning, a good example being a project where ACE Technology was contracted to ‘composite engineer’ a complete LMP sports racing car. This required ACE to use its experience in geometric optimisation of composite materials, while working to stringent mass targets and crash testing requirements. Optimising geometry involves first digitising and capturing the existing design or the existing shapes to re-design within.
“It was during such applications that we realised the portable arm solution is really not so portable,” begins company director, Paul Skinner. “Our services often mean travelling across the UK to visit customers, and immediately a large heavy tripod becomes a concern both logistically and from a health & safety consideration. In addition, mounting an arm inside a vehicle offers two problems; access, and more importantly the vehicle moves as you enter, hence any datums set are immediately lost and subsequently all data is useless.”
ACE therefore decided to evaluate developments in 3D scanning and also consider new portable technology. The brief was simple; portability, an ability to scan a variety of materials including carbon fibre, epoxy tooling material, virtual mirror surfaces and polished aluminium, and easy-to-use software that would improve their current workflows. The project was handed over to Edward Smith, an engineering intern within ACE Technology.
Made to measure
After assessing two of the major portable arm suppliers and their respective laser line scanners, Smith quickly realised that such solutions still had the same limitations as before, namely, a lack of portability and manoeuvrability around the scan subject.
As an alternative, trials were carried out using an optical solution based on the Creaform MetraSCAN and HandyPROBE Elite from Measurement Solutions, and it soon became obvious that this new technology was able to solve the problems previously associated with a measuring arm.
Smith comments: “Having used an early version of the MetraSCAN at a previous company, I was familiar with the concepts and benefits of the Creaform system compared to traditional measurement arms – such as superior scan speed, manoeuvrability around the subject, and consistent accuracy. With the latest developments in the MetraSCAN, the scan quality of mirror-like surfaces and carbon parts were exceptional.”
Skinner continues: “We actually had Measurement Solutions come back to visit us twice - we simply couldn’t believe how this system was two or three times faster than everything else we had witnessed.” As a result of the trials, it didn’t take long to decide to acquire a system.
Resource allocation and personnel training were also important in the decision-making process, explains Smith: “We didn’t want to dedicate a specialist to this equipment. Design and manufacture are the main priority for us. Therefore, we were seeking a product with a relatively friendly learning curve that several technicians could pick up and use intermittently, sometimes weeks apart.”
The VXelements software suite supplied by Measurement Solutions meets these criteria. Previously during a reverse engineering process, data was exported and modelled within a SolidWorks plug-in or via another complex third-party point cloud software. With the introduction of VXmodel software, a live transfer enables surface ready data and section cuts to immediately appear in SolidWorks for final modelling or design updates.
The MetraSCAN was also supplied with the HandyPROBE, a handheld, wireless probing system that enables users to probe features, just like a measuring arm. Both systems work independently as handheld accessories and are tracked by an optical camera system called the C-Track, providing six degrees of freedom over a 16m3 volume. The HandyPROBE dynamically reports a cartesian co-ordinate of a component or tool datum, which can be used to build tools and set nominal positions or report surface deviations to a nominal CAD file.
Similar approaches used in F1 and aerospace tooling utilise either a portable arm and a laser tracker, or a laser tracker with a handheld probing and scanning solution – both solutions present significant mobility limitations around the scan area. As with any large volume build or inspection during the measurement, ‘line of sight’ must be maintained between the laser source (tracker) and the probing device. This normally requires a ‘device move’ at some stage, requiring the measurement of a network of targets both before the measuring device can be moved and again once relocated. This process adds complexity and therefore a high potential for operator error, plus it adds significantly to the measuring time. The C-Track solution automatically and dynamically re-aligns using the optical cameras, removing all of the complexity and significantly reducing the measuring time.
Onwards and upwards
In the coming months ACE Technology will finalise a new accreditation and supplier compliance for further growth into the aerospace sector as composite components continue to expand in their application. It has also invested in a Markforged 3D printer to offer fibre reinforced nylon tooling and components.
“The MetraSCAN plays a fundamental role in enabling us to adopt this new technology, by capturing data from patterns, tooling or final parts that we can quickly convert into files suitable for 3D printing,” Skinner concludes. “While we can print end-use parts, the technology will be used to print items for use on jigs, templates and fixtures, thereby reducing the time required when developing our various composite production processes.
“The MetraSCAN is a key investment to support our Scan2CAD initiative over the coming years, and with support from the Measurement Solutions team we’re confident that this will play a vital role in our continued and aggressive expansion.”
