Virtual Inspection of Additively Manufactured Parts

Advanced manufacturing techniques, such as additive manufacturing, enable the design of increasingly complex components for a wide range of industrial applications. However, this complexity makes qualification of the parts, determining whether a part is within some margin of error from the initial design, difficult. To inspect and qualify complex internal geometries that are not accessible with an external probe, parts are typically scanned with computed tomography (CT), and manually compared to the computer-aided design (CAD) model using visual inspections. Matching the CAD model to the 3D reconstructed object is challenging in a traditional desktop environment due to the lack of depth perception and 3D interaction. An additional challenge comes from the geometric complexity of CAD meshes and large-scale CT scans. We present a virtual reality (VR) system for manual qualification, providing a novel defect visualization method. First, we describe a semiautomatic CAD-to-Scan Registration approach in VR using a finite element mesh. Second, we introduce the Defect Box, which enables full-resolution inspection for massive scans and CAD-CT comparison of local defect regions. Finally, our system includes intuitive 3D Metrology methods that enable natural interactions for the measurement of features and defects in VR. We demonstrate our approach on both real and synthetic data and discuss feedback from four expert users in nondestructive qualification.