Session: ASME Undergraduate Student Design Expo

Paper Number: 176063

Accuracy Validation of a Consumer-Grade Structured-Light 3d Scanner 

Reverse engineering is a crucial tool in modern mechanical engineering, enabling the replication, redesign, and optimization of components. The traditional process can be time-consuming and expensive, requiring either labor-intensive manual measurements or costly industrial scanners and laboratory conditions.

This project examines the applicability of a consumer-grade structured-light 3D Scanner (i.e., Shining 3D EinStar) in the automotive reverse engineering of a 1984 Dodge D150 Truck frame to accept the front and rear subframe suspension off a 2022 Dodge Challenger SRT. Precise models of all frames were necessary to design a set of adaptation brackets that permanently connect the suspension to the main frame, while preserving proper suspension and drivetrain geometry.

The process initiates with multiple three-dimensional scans of the truck frame and Challenger subframes utilizing the EinStar scanner. Given the low chance of exactly replicating laboratory conditions in a real-world engineering setting, all procedures were performed in a standard workshop environment without using more extensive measures than basic scanning aids like infrared dots and scanning spray. Each component was scanned three times. Afterward, each scan was aligned, cleaned, and converted into a mesh file using ExStar. The digital geometry was then replaced in ExModel, and the components were assembled in SolidWorks using STEP files. The average of three scans for each component was used to ensure measurement repeatability and accuracy.

The digital models were aligned in SolidWorks to ensure proper centering of the subframe, ride height, and drivetrain geometry before designing brackets. It was essential that the rear differential input shaft be parallel to the ground to prevent noise and vibration during operation. A series of fitment brackets was designed based on measurements from the aligned assembly, then 3D printed using standard PLA filament. In three separate experiments, involving a total of ten brackets, each 3D-printed bracket fit precisely, securely bolted into position without interference or visible deformation, thereby confirming geometric accuracy prior to the design of load-bearing components. Physical measurements indicated an average deviation of 0.41 mm across five tests; however, due to tool tolerance limits of (+/- 1 mm), the primary method of verification was the bracket fitment. Employing two verification methods ensured both redundancy and confidence in the results.

This study demonstrates that a consumer-grade 3D scanner can achieve sub-millimeter accuracy suitable for structural automotive reverse engineering, providing an affordable, repeatable solution for engineers. Approaching the problem in this manner enables engineers to produce a digital twin of intricate vehicle assemblies and to efficiently validate designs through physical fitment. These critically assessed findings confirm that this workflow can deliver fabrication-ready dimensions under typical shop conditions, enabling a streamlined process for complete retrofits at a fraction of the cost of traditional reverse engineering.  

 

Acknowledgment:

This research was supported by the Mechanical and Civil Engineering Research Experiences for Undergraduates (MCREU) program at Penn State Scranton, which provided funding for the project. The authors also acknowledge the Department of Mechanical Engineering at Penn State Scranton for providing access to SolidWorks software and related resources.

Presenting Author: Grant Lewis Pennsylvania State University of Scranton

Presenting Author Biography: Grant Lewis is an undergraduate student pursuing a B.S. in Mechanical Engineering at Penn State Scranton. His current research focuses on validating the accuracy of consumer-grade structured-light 3D scanners for use in reverse engineering and automotive applications. As Vice President of the Penn State Scranton Engineering Club, Grant actively works to create opportunities that educate and promote meaningful learning experiences for fellow students. His academic and professional interests include mechanical design, advanced manufacturing, and applied research in automotive systems. He plans to continue his education and pursue a career in mechanical and automotive engineering.

Authors:

Grant Lewis Pennsylvania State University of Scranton
Farhang Daneshmand Pennsylvania State University of Scranton
Pinlei Chen Pennsylvania State University - University Park