In the foundry industry, every step of production requires high precision and comprehensive optimization. In the past, foundries often relied on traditional measuring tools such as coordinate measuring machines (CMMs) to check product quality. However, this method was time-consuming, easily causing bottlenecks in the process and delays. In this context, 3D scanning technology has emerged as a powerful, modern solution that helps to comprehensively improve the production process from start to finish.
3D scanners such as MetraSCAN 3D allow for the collection of detailed, accurate and complete data of the casting surface at every stage of production. This allows technicians to quickly check geometric conformity, detect errors and compare with CAD models. In addition to being an effective replacement for CMMs, 3D scanners extend their applications to quality control, tool validation, deformation analysis, and reverse engineering.
The molding process begins with prototypes and tools. Using a 3D scanner at this stage helps verify dimensional accuracy and conformance to the design. When deformation or shrinkage is detected, the scan data allows timely adjustments to the mold design, preventing errors from spreading.
In addition, 3D scanning is especially effective when measuring deep cavities or hard-to-reach features – areas where CMMs are often limited by probe configuration or discrete measurement points. Thanks to the comprehensive point cloud data, technicians can detect any geometrical deviations that traditional methods may miss.
After prototyping, 3D scanners are used for prototype verification and first-product inspection (FAI). With comprehensive data collection capabilities, technicians can easily detect defects such as porosity, warping, or misalignment due to uneven cooling – defects that often greatly affect product durability and quality.
Visual color maps from inspection software help to accurately compare the casting part to the CAD design. This process not only saves inspection time but also shortens the approval cycle (PPAP) thanks to the ability to generate automated, accurate, and transparent reports.
During the mass production phase, 3D scanners play an indispensable role in continuously monitoring product quality. When non-conforming parts are detected at an early stage, the foundry can intervene immediately, avoiding wasted materials and rework costs.
In addition, by tracking deviations at each stage, 3D scanning data allows for the analysis and root cause treatment of system problems – from mold design to heating temperature or hot metal runner layout.
Beyond inspection, 3D scanning also supports the optimization of the overall casting process. By comprehensively scanning the piping, nozzles and molds, engineers can analyze the metal flow, thereby designing a more optimal gating system, minimizing material loss.
In particular, 3D scanning technology helps analyze thermal deformation, detecting expansion or contraction due to temperature – a key factor in ensuring the dimensional stability of molds and castings.
Before machining a part, accurately aligning the casting is an important step. Instead of using costly fixtures, 3D scanners can be combined with software to automatically determine reference points, thereby aligning the CAD model optimally. This increases accuracy while reducing production costs by eliminating custom fixtures.
From mold making, prototype inspection, mass production to machining alignment, 3D scanners serve as a comprehensive and flexible measurement tool in the foundry industry. Not only replacing traditional measuring devices, 3D scanning also opens up a new approach, helping foundries better control quality, minimize errors and optimize the entire production process. This is the key to moving towards high-precision, faster and more efficient production in the modern industrial age.
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