What customers do

ATOS is used in development, quality control and production to reduce time and costs. Application areas include 3D inspection, reverse engineering and rapid manufacturing.

3D Inspection

Measurement data from ATOS Core forms the basis for the 3D inspection and quality assurance of parts and components – for example sheet metal, tools and molds, turbine blades, prototypes as well as injection and pressure die casted parts. The 3D digitizer scans the complete surface of a component without contact. Using millions of measuring points, ATOS software automatically calculates the 3D coordinates in the form of a high-resolution point cloud (STL triangulated mesh). This polygon mesh describes the free-form surfaces and geometries that can then be compared to drawings or directly with the CAD dataset for shape and dimension analysis.

Deviations to the CAD dataset are displayed in color, meaning correction measures are self-explanatory. Multiple 100-page long, classic table-based reports shrink down to just a few illustrations and functional measurements.

The GOM Software offers numerous possibilities for evaluating the measurement data from ATOS Core; including drawing-based or CAD-based inspection methods. Drawing-based inspection is based on classic workflows from tactile coordinate measurement machines. For CAD-based inspection, the GOM software features numerous interfaces such as IGES, JT Open, STEP, CATIA, NX, Solidworks and , Pro/E. FTA elements (Functional Tolerances & Annotations) and measurement plans (CSV-, DMI-, ASCII-, IPP) can be also be imported into the software.

Surfaces, cross-sections, and points can be compared in the software with the CAD data to analyze parts and components. Based on the nominal data, additional regular geometries (lines, planes, circles, cylinders) can be generated. The software also allows curved-based inspection for example the analysis of gap and flush, spring-back as well as form and character lines. . Additionally, the software contains tools for GD&T analysis, allowing the dimensions, the form and the position of characteristics to be determined and ultimately ensure the function of the component. To analyze identically constructed parts, an additional trend module is available that can detect the component variations in serial production.

Reverse Engineering

ATOS Core measures millions of measuring points with finest details. ATOS software automatically calculates the 3D coordinates in the form of a high-resolution point cloud (ASCII/STL). The calculated polygon mesh describes free-form surfaces and regular geometries and establishes the base for creating a CAD model during reverse engineering.

For reverse engineering the scan data into mathematically described surfaces (NURBS surfaces) or solids, the data can be exported as a STL or as an ASCII point cloud. The export of cross-sections, tape and contrast lines as well as geometries in IGES format is possible. The actual conversion of the scan data into a CAD surface model requires special software packages.
Some CAD programs currently include modules for reverse engineering.

To make sure that the CAD surfaces correspond to the scanned data, this newly created surface data can be imported into the ATOS software. Afterwards, the deviations of the two datasets can be calculated and visualized using false color plots.

Reverse engineering is used primarily in design and product development to digitize manually created design models, for example in automobile and prototype construction, as well as transferring manual changes to the models to the CAD. In product development in particular, the measurement data improves the simulations because it ensures that the actual form of the model matches the form of the computer model that is used in the simulation.

Machine construction is also an important field of application for reverse engineering. Not only can CAD data be generated, for example for older tools or duplication, but manual changes on the tool can also be transferred back into the CAD dataset during testing or repair.

Rapid Manufacturing

Processes such as 3D printing as well as other additive manufacturing processes (SLM, SLS, FDM, DMLS, etc.) make it possible to construct and realize component geometries by means that where not possible to date using conventional production methods. The main focus is on organic constructions and free-form surface that satisfy high haptic, ergonomic, and visual requirements.

ATOS Core provides quick 3D acquisition from any type of component for in-house 3D printing. Without any further processing, the generated 3D dataset (STL) can be copied in the 3D printer and reproduced.

Methods such as 3D printing and other additive manufacturing processes allow the design and manufacture of component geometries, which in the past were not possible to produce with conventional processes.

Mostly, these geometries consist of organic designs and freeform surfaces. With ATOS Core, the complete surface of any component is scanned quickly. Without further processing, the resulting 3D data (STL) immediately can be copied and duplicated in a 3D printer. The data can also be edited and changed – for example in the free software GOM Inspect. With this technique, customized items are produced as a mass product, for example in the dental field or in hearing acoustics.

Since the component geometries often consist of complex free-form surfaces, their shape and dimensional accuracy can only be verified with optical measuring systems such as ATOS Core. Particularly in prototype and small series production, the inspection of the geometry and function plays a crucial role. In this area, ATOS Core is used for the inspection of molds and mold inserts, which were produced with additive manufacturing processes. The system is also used for the shape and dimensional analysis of components during mold try-out.