Carl Zeiss Optotechnik GmbH - Optische Messtechnik
Tuesday, 01 August 2017 13:13

3D sensor optimizes 3D printing

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ZEISS COMET LƎD enables the research institute Wood K plus to carry out a nominal-actual comparison. 

SYSTEM / APPLICATION
ZEISS COMET LƎD 

FIELD
Research and development 

CUSTOMER
Kompetenzzentrum Holz GmbH (Wood K plus) 


TASK 
Kompetenzzentrum Holz GmbH or Wood K plus for short is a leading research institute for wood and related renewable raw materials in Europe, located in Linz, Austria. Around 115 employees in five research areas at four locations (Linz, Tulln, Lenzing, St. Veit) are currently researching how renewable raw materials can be finished and processed for innovative applications and used for high-tech applications.

The fact that the scientific output of the competence center is internationally recognized is documented by many, in some cases highly ranked publications. In 2015 alone, the team from Wood K plus published more than 100 articles in refereed scientific journals and conference papers, as well as in trade journals and books. In addition to this, the center counted more than 50 ongoing academic works in the same year.

An important focus of research of the scientists in the field of wood-polymer composite materials is the development and processing of composites of renewable raw materials and thermoplastics (WPC: Wood Polymer Composite and NFC: Natural Fiber Composite), including with the use of 3D FLM printing. This is a theme that is of great interest for many companies from the industry due to its enormous practical relevance. In the context of a new international pilot project (Interreg Austria-Bavaria 2014-2020; technology and research platform "Hybrid Materials", AB97), the Kompetenzzentrum Holz was able to expand its infrastructure in Linz with additive production with 3D FLM printing.

In order to be able to manufacture high quality work pieces with this still innovative process, the deviations of the 3D-printed parts from the nominal values of their CAD model must be definable. In 2016, Wood K plus therefore invested in a ZEISS COMET LƎD that for the first time enabled researchers to carry out analyses of this kind.

SOLUTION AND PRODUCT
The Austrian scientists decided in favor of the strip projection sensor of Carl Zeiss Optotechnik GmbH especially due to its precise measurement results, which are "indispensible" for making qualitative statements about the nominal-actual deviations of the ongoing project in the field of wood-polymer composite materials."
The ZEISS COMET LƎD is an innovative sensor for the recording of 3D data that is based on the measurement principle of strip projection and blue LED technology. Here a strip pattern is projected onto the respective measurement object using the blue LED light. This pattern is specifically distorted due to the geometry of the respective component, and is recorded by a camera.

The intuitively operated ZEISS collin3D software subsequently uses triangulation calculations to establish a relationship between the individual camera pixel and a point on the work piece. The point cloud created in this way is then transformed to the so-called triangular network in the STL format, with which a 3D model can be generated. This is then drawn upon using the inspection software INSPECTplus, also from ZEISS Optotechnik, for the nominal-actual comparison with the 3D CAD model.

RESULT / BENEFITS FOR THE CUSTOMER
Only a few hours were required to launch the ZEISS COMET LƎD for practical usage. Because, according to the employees, handling is "easy and intuitive“, all of those trained could subsequently work independently with the ZEISS COMET LƎD after a brief introduction by ZEISS. After several weeks of intensive usage, the employees of the Kompetenzzentrum Holz were then introduced to the fine points of the system. Thanks to this detailed ZEISS workshop, which took place over several days, "we can now exploit the complete potential of the system."

The Austrian research institute Wood K plus currently uses the ZEISS sensor especially for the analysis of the components created with 3D printing or for the detection of deviations from the nominal geometry defined in the CAD model. Thanks to the precise measurement results, the scientists in Linz are able to adapt the printing process as hoped in such a way that, depending upon the material, the nominal-actual deviation already lies within the strived for or prescribed tolerance range after 2-3 test runs.

In addition to this, the employees can also digitalize various injection molding parts with the ZEISS COMET LƎD. "This makes it possible to evaluate and correlate the process-related differences with regard to the shrinkage behavior of the respectively used materials in the injection mold in comparison with the 3D print more quickly than previously.”

ADVANTAGES / STATEMENT
- "The price-performance ratio of the ZEISS COMET LƎD is convincing: we received an extensive system with a high degree of flexibility and performance capability at a fair price."
- "We were looking for an exact digitalization system. The ZEISS COMET LƎD fulfils our requirements, which is why we consciously chose it."
- "We use the ZEISS COMET LƎD to analyze whether the components manufactured with 3D FLM printing deviate from the nominal geometry (CAD). With this information, we adapt the printing process in such a way that the prescribed tolerances are observed."
- "Thanks to the time savings achieved through the adjustment of the process parameters for the required tolerances with the assistance of the data, investing industrial companies can anticipate a quick return on investments on the foundation of our development results."
DI Josef Ecker, scientific employee and lecturer on wood-polymer composite materials, Kompetenzzentrum Holz GmbH


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Carl Zeiss Optotechnik GmbH
Georg-Wiesböck-Ring 12
83115 Neubeuern, Germany
+49 8035 8704 0


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