Zoom-Enabled Optical 3D Scanner Made Flexible for Inspecting Complex Molds

Hexagon’s Manufacturing Intelligence Division has announced the launch of a new type of high-productivity structured light scanner, the SmartScan VR800. Built on a completely reengineered platform, the optical 3D scanner is equipped with a motorized zoom lens that enables users to adjust data resolution and measurement volume entirely through software settings. This greatly improves the productivity of quality inspection, and further improves workflows with more efficient post-scanning alignment processes, including the ability to combine scans of different resolutions within a single project.

The technology’s noncontact and high-speed structured light scanning (also known as white light scanning) is ideal for molds, which are often made of complex or free-form shapes that are difficult to measure with tactile methods. Moreover, the VR800’s combination of four 20 MP cameras in a dual stereo setup (for wider range of measurement volume) and optical zoom-enabled projection (for varied volumes and resolutions within each volume) enables it to take accurate measurements at different zooms/depth of field in a single pass.  

Three new software functions — Smart Resolution, Smart Zoom and Smart Snap — allow the user to customize inspection resolution and measurement volume with no mechanical alterations to the system. This means data-heavy, high-resolution scans can be focused on the feature-rich areas that matter most, while other areas can be covered more efficiently by larger and/or lower resolution scans.

Additionally, the system’s integrated controller unit provides fast pre-processing of scan data on the device, ensuring the data heading into the metrology software is cleaner and easier to use. A custom-built carbon fiber frame ensures thermal stability and allows for longer intervals between calibrations.

The VR800’s Smart Snap function in particular delivers optimized workflow efficiency, even on parts where everything needs to be scanned at higher resolutions. This mode uses the larger base camera pair to take an LED flash-supported alignment image at the same time as the smaller base camera pair performs a full high-resolution 3D scan. Each scan section is now paired with an alignment image, for more efficient knitting together of the scan data.

As with other structured light scanners from Hexagon’s range, the VR800 can be paired with a turntable or turn-tilt unit to enable semi-automated measurement workflows. The VR800 is also ready for integration within robot- or cobot-based fully automated inspection systems.