Jan
11
2014

FARO ‘casts’ a spell on Hadleigh quality

FARO ‘casts’ a spell on Hadleigh qualitySince 45 years, Hadleigh Castings has established a reputation as one of the UK’s leading aluminium foundries. The company’s extensive range of aluminium casting technologies and services includes CAD CAM, Pattern Making, Boxless Sand Moulding, Precision Sand Casting, Gravity Die-Casting CNC Machining, Final Finishing and Product Assembly.

Robin Mills, Hadleigh Castings Business Standards Manager explained. “Having looked at several alternative systems that could further improve our quality function and help to increase the flow of our inspection work, we decided to purchase an Edge ScanArm system. Compared to the other available systems, the ScanArm proved to be the ideal tool for product development, inspection and quality control functions.

“Adopting non-contact measurement techniques has considerably speeded-up our 1st article measuring process and significantly reduced our new products’ time to market. An example of the considerable time advantages that we have gained through the use of our FARO ScanArm is the regular detailed inspection that we undertake on a very complex casting. Previously, the painstaking, very precise inspection routine took us over 30 hours to complete. Now, with the use of our FARO Edge ScanArm, we are able to accomplish the complex task with improved levels of accuracy in less than 4 hours” pointed out the Hadleigh Castings Business Standards Manager.

The speed of operation of our new FARO ScanArm has enabled us to significantly speed-up our inspection processes“Given our ever shorter project lead-times, the ScanArm will be utilised to fast track, confirmation of the dimensional alignment of new or modified sample parts against the customer supplied 3D models. Also, as Faro’s software uses graduated colour graphics to indicate the tolerance condition of components’ features, in addition to tabulated reports, we are now also able to supply customised reports containing detailed graphical information ” emphasized Robin Mills.

Robin Mills concludes. “In addition to improving our accuracy capability, the speed of operation of our new FARO ScanArm has enabled us to significantly speed-up our inspection processes. The man hours saved by the use of the FARO Edge ScanArm will ensure that our return on investment time will be even faster than first estimated.”

Read about the ScanArm applications for foundry

About Hadleigh Castings
Hadleigh Castings was founded in 1968 to provide a full aluminium casting and manufacturing service.

Over the years continued investment in technology and training has created a modern, high quality production facility capable of producing precision sand casting and gravity die casting to very close tolerances.

As a leading sand and die foundry we are Professionals in producing quality castings of exacting standards. and consistently produce quality aluminium products for major manufacturers, especially in the UK and European markets, and also for other regions in the world.

Jan
07
2014

On Top of Things: 5 Reasons Why You Should Be Measuring On-machine

No, Marvin Gaye never sang about manufacturing. If there is but one takeaway from the R&B legend’s soulful catalog, it is this: let’s get it on (machine). For too long, many of you have brought heavy part after heavy part to your fixed CMM for inspection, ignoring that a simpler, more accurate and less taxing solution exists. You should be inspecting and measuring in-process or finished parts on (or near, I suppose) the machine tool. Here’s why.

1) Environmental Flexibility: Still paying (and working) to maintain a climate-controlled inspection room to house your fixed CMM? Well, stop it. Portable CMMs adapt to the typical factory floor environment. Plus, you’ll reduce machine interruptions during the machining process because the part won’t have to travel to another location for inspection.

2) On-the-spot Analysis: With a portable CMM, users can accurately verify their processes and setups with just a few button clicks. Proper tool and part alignments can be validated before machining critical features. Features can be analyzed after each step of machining. So, problems can be diagnosed quicker, leading to reduced inspection times.

3) Tool Wear Detection: Using a portable CMM can detect if a part is out of spec, true-enough. But, the data collected can help detect if the tool itself is degrading.

4) Time Savings: Tired of walking heavy parts to and from the inspection area? Had enough of lost time due to rework because you didn’t catch part deformities on time? Can’t stand waiting for your machine tool get going after you, again, had to shut it down to go inspect a part? Just asking.

5) Cost Savings: The proverbial “all of the above” answer here. Lost time due to machine outage, out-of-spec parts, tool wear and travel time cost money? Want to save money, effort and potentially days of downtime? Get yourself a portable CMM and start measuring on-machine.

Nov
26
2013

Visualisation and interaction software specialists explore the insides of a mummy

Scanning inside a mummy with the FARO ScanArmMuseum visitors in Stockholm will soon be able to explore a real Egyptian mummy in a virtual autopsy that combines three scanning technologies for a ground-breaking new level of realism.

Since archaeologists first dared to enter the pyramids, the public has been fascinated by the exploration of relics from ancient Egypt. Now visitors to the Museum of Mediterranean and Near Eastern Antiquities – Medelhavsmuseet in Stockholm will be able to virtually peel away the layers and actually look inside real mummies that have been carefully guarded for more than 4’000 years.

The experience will be powered by Inside Explorer, a tool developed by Interactive Institute Swedish ICT. Thomas Rydell, Studio Director at Interactive Institute, heads the team of visualisation and interaction software specialists behind the project. He says “The ‘Inside Explorer’ system is already in use in a number of museums, but the textural detail of the mummy exhibit due to open in early 2014 is unprecedented.”

The mummy was taken to a hospital for a Computer Tomography (CT) scan, which provided volumetric information of the inside of the mummy. But CT scans do not provide sufficient surface detail. This is where FARO stepped in to help.

Visualisation and interaction software specialists explore the insides of a mummy

A FARO Edge ScanArm was used for the 3-day mummy scanning session, which was conducted by members of the Interactive Institute team and Autodesk: “We are software engineers and not measuring experts but we were able to use the FARO hardware almost immediately,” says Rydell. “FARO came in to help us get started and to check a few things that we might have otherwise missed.” The members of the team were swapping roles all the time and taking photogrammetric images, “so the ease of use and mobility of the FARO device was a huge enabler,” explains Rydell.

Now, with the mummies safely locked away to protect them from UV or physical damage, post processing is underway. Autodesk reality computing software is being used to create detailed textured meshes from the regular 2D photos and the cloud-point data.

The volumetric data from CT scanning and the textured mesh data from the surface scanning will then be combined in Inside Explorer, Interactive Institute’s own real time rendering software, creating an accurate digital representation of the mummy. Museum researchers or visitors will then be able to use simple gestures to explore the mummy as a whole, zoom in to see fine detail or go below the surface. “Thanks to the 3D scans of the surface, we have the possibility to get enough surface resolution to establish a powerful and realistic first impression,” says Rydell.

Users can also remove the sarcophagus, peel away the layers and explore the inside of the exhibit.

Oct
30
2013

Webinar – Make inspection work for you with Geomagic® Control™ and the FaroArm

Webinar – Make inspection work for you with Geomagic® Control™ and the FaroArmDuring this webinar – November 21st – we will explain how you can use the FaroArm’s touch enabled probe and laser line probe to improve your inspection process using Geomagic Control’s intuitive inspection platform.

The goal of this webinar is for you to discover how to eliminate workarounds during the inspection process without missing any detail.

With Geomagic Control and the FaroArm, you can create and run purpose-built inspection processes that do exactly what you need.

The presenter of this webinar is Marco Albrecht, Geomagic Solutions Technical Evangelist.

Agenda:
- Live demonstration via a step by step inspection process showing how FARO works inside Control
- Introduction of the Auto Batch Process
- Q&A

Date: Thursday, 21st November 2013

Time:
9:00 AM – 10:00 AM EDT (New York)
2:00 PM – 3:00 PM GMT+1 (London-Dublin)
3:00 PM – 4:00 PM GMT+2 (Berlin-Paris-Rom)
4:00 PM – 5:00 PM GMT+3 (Istanbul)

You can registere here for this webinar, free of charge.

Sep
23
2013

The new FARO ScanArm presents itself

Below video let’s you meet the latest advancements in laser line scanning sensors.

Materials with dark or reflective optical properties can now be scanned with less effort and without sprays or coatings.

Watch the video and read more @ www.faro.com/scanarm

Sep
19
2013

How to customise an engine bay hood for the Ferrari 458 Spider?

Capristo, specialist in exhaust systems, demonstrates how to customise carbon production for automotive parts.

In this video Capristo and FARO experts show the entire manufacturing process of an engine bay hood for the Ferrari 458 Spider.

It starts with creating a 3D picture using a 3D laser scanner which forms the basis for the development of the prototype. The scanned data are then prepared, cleaned and exported in such a way that these can be further processed using CAD-Software. Have a look what happens next…

Aug
30
2013

Measurement at Mercedes-Benz

Have a look and see how Mercedes-Benz uses the FARO ScanArm to design and produce its M-Class.

Aug
12
2013

Software that thinks for itself – for both inexperienced users and trained professionals

Software that thinks for itself – for both inexperienced users and trained professionalsCAM2 SmartInspect software allows measurements without CAD data. The software was developed, focussing on a simple and intuitive operation and on a short learning curve. Even users with minimal knowledge of 3D measuring technology can achieve accurate measuring results in a short period of time.

The basic version of CAM2 SmartInspect has a clear user interface besides the most relevant functions. Actual pictures of components can, for example, be added to every measurement process providing the user an image-based support.

In the pro version of CAM2 SmartInspect the user is shown a 3D live view that serves to present the recorded dimensions to optimum effect. On the one hand it provides the user with a quick orientation. On the other hand, features that measure length, angle or a combination of both, can be recorded directly on the screen.

The automatic feature-recognition function speeds up the measuring process, as it assists the user in processing a measuring sequence with few, if any, clicks.

Another advantage: the software thinks for itself! It automatically suggests a range of functions and commands which might be needed in the course of the measuring process. In this way, inexperienced users get tips and tricks regarding the software’s capability and professionals can use this function to speed up the working process.

Jul
26
2013

Jaguar gains speed and precision

Faro's 3D measurement systems permit high-precision 3D measurement, imaging and comparison of partsJaguar Land Rover (JLR) is the UK’s largest automotive design, engineering and manufacturing employer and operates from 5 sites in the Midlands and the North of England.

To help satisfy the rapidly growing global demand for its cars, JLR plans to deliver 40 significant product actions over the next five years.

“In addition to using portable measurement systems for the validation of BIW structures, it is also used for measuring panels in both pre-production and production runs. The outstanding levels of accuracy and repeatability that we are able to achieve through our use of FaroArm Platinum and the Laser Line Probe, ensures that we can detect micron deviations from our CAD models, BIW Supervisor, Martyn Smith explains.”

More details on how Jaguar gains speed with portable measuring systems

Jul
15
2013

What to do when CAD-files are non-existent or lost?

Find out in this one-minute video how to reverse engineer a piece with the FARO Edge ScanArm. After quickly scanning a part with the integrated laser scanner arm, surface models are created that can be used for surface reconstruction or reproduction of a component.

Reverse engineering of components permits the generation of CAD files of parts whose plans are either non-existent or were lost. It is also used to update or create documentation of the existing, as-built situation. Users can quickly scan a room or object and create surface models that can then be used for surface reconstruction.



FARO Europe Blog

FARO’s portable measurement equipment permits high-precision 3D measurements production and quality control. Products include the measuring arm FaroArm, the personal CMM FARO Gage, Laser Tracker ION and Laser Scanner Photon.

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