Scan heli canopy to create a CAD file?

[trillian]

Does anyone have experience scanning an object to create a file for 3D printing?

I have spoken to a company that does 3D printing and they say they can print a canopy that I want to duplicate. (I have described the shape and construction as well as I can verbally, so hopefully they understand the requirements).

They say they can scan it but charge £120.00

I have seen something about creating a scan with a camera or phone, just curious if anyone has done some scanning and what was required to get it accurate enough.

[Gixxer]

I dipped my toe into 3D scanning a good few years ago, using an Xbox 360 Kinect sensor connected to the PC, and Skanect software. The results were quite good, and probably plenty good enough for something as simple as a canopy, but I wasn't doing 3D printing at the time, so I never got the chance to print anything I'd scanned, but, coincidentally, I was recently asked to reproduce a part for a vintage car, so I've decided to have another go at it, and I'm currently building a turntable to scan the original part for 3D printing (a turntable isn't necessary, I just want to automate the process). Unfortunately, I'm a few weeks away from moving house, and the project has been put on the back burner again, so I still can't comment on how effective it will be, but it should work just fine.
Here's an example of the Kinect sensor and Skanect in action.

The free version of the Skenect software wouldn't export enough polygons for a smooth canopy, but you could download a free trial of Autodesk Netfabb to smooth the mesh, then export the STL file for slicing in your favourite slicer.

Alternatively, have a look into photogrammetry apps for your phone.

[mole hunter]

Hi trillian,

I've no idea what size or complexity of canopy you are wanting to replicate and not sure a 3d printed version would be the way forward. I know there's a range of materials out there but they would all need a fair bit of post-print finishing. Also, if it won't fit within a desktop printer - it's gonna be expensive through Shapeways for example!

Other than scanning - what about drawing/modelling it up? The attached images are a half hour doodle on Fusion 360. If the inside surface could be filled and smoothed it could be used as a mould maybe for GF epoxy layup?

Cheers, Marty

[trillian]

The canopy I want to duplicate is a very simple shape. It's a one-off custom made design that is basically the same shape as a TDR only a bit taller.

I have been quoted £100.00 to print three, which I think is very good. But I don't know what material and if they fully understand what a canopy needs.

Another idea would be to use a sacrificial TDR canopy, mod it to the right dimensions, then cut it in half and fill the inside with something to make it rigid and use it as a positive mould for vac forming. Back in the days before all the elaborately painted canopies, the standard construction was vac forming in two halves and gluing them together. I have some canopies made this way and they look good and are very light. I need to speak to a vac forming company to find out what it would cost though. In theory it should not be expensive if I am providing the mould.

Hi trillian,

I've no idea what size or complexity of canopy you are wanting to replicate and not sure a 3d printed version would be the way forward. I know there's a range of materials out there but they would all need a fair bit of post-print finishing. Also, if it won't fit within a desktop printer - it's gonna be expensive through Shapeways for example!

Other than scanning - what about drawing/modelling it up? The attached images are a half hour doodle on Fusion 360. If the inside surface could be filled and smoothed it could be used as a mould maybe for GF epoxy layup?

Cheers, Marty

[Ade_Law]

honestly it would cheaper and be more satisfying to use it to create a glass fibre mould, then you can make as many canopies as you want, glass is easy to work with and requires very little tools, the only thing you might want to take a look at is vac bag equipment but its not required.

plenty of guides on youtube about this kinda stuff

Ade

[trillian]

I'd like to find out exactly how he did this one. (talks about canopy at 2.00 but not much detail) https://www.youtube.com/watch?v=euYDrdslzgE

honestly it would cheaper and be more satisfying to use it to create a glass fibre mould, then you can make as many canopies as you want, glass is easy to work with and requires very little tools, the only thing you might want to take a look at is vac bag equipment but its not required.

plenty of guides on youtube about this kinda stuff

Ade

[Gixxer]

I'd like to find out exactly how he did this one. (talks about canopy at 2.00 but not much detail) https://www.youtube.com/watch?v=euYDrdslzgE

This is the process he used.

[trillian]

Thanks! That is incredibly cool

I actually already have a vacuum pump, in fact I have two different ones because a long time ago I was going to build a vac forming machine, but then sidelined that project when I moved back up to London.

This is the process he used.

[Ade_Law]

this is a fairly good video,

https://www.youtube.com/watch?v=R8RpdeNXwMI

when you make the mould a couple of wood braces across the canopy to stabilise it whilst you make the mould would be a good idea. Its not difficult and once you have the mould you can make as many canopies as you wish.

Ade

[trillian]

I will be speaking to Easy Composites soon. Looking on their website they have a kit that uses some type of putty that you can apply to an object and create a layer a couple cm thick, which then hardens to form a mould. In any case I will talk to them describing what I want to do.

I have the basic tools to make things like wooden frames and supports and at the moment I have a spare room I can use, so it's totally possible

[Mike Sanders]

Good luck. Don't forget to take photos.

[trillian]

Good luck. Don't forget to take photos.

Yes indeed. Speaking of photos, I think it would be interesting to see the facilities at Canomod or SAB for the Goblins, and video of actual heli stuff (in GRP) being made. I've never searched for anything like that.