Additive manufacturing and digital replicas made easy with Creaform’s metrology solutions

The Marshall Advanced Manufacturing Center (MAMC) is a is a leading-edge resource facility dedicated to driving innovation and advancing manufacturing technologies.

Operating from facilities in Huntington, South Charleston and Point Pleasant, West Virginia, the MAMC is at the heart of groundbreaking solutions, such as 3D scanning, additive manufacturing, and rapid prototyping. Serving industries and individuals alike, the center leverages advanced technologies to provide exceptionally accurate 3D data for design, production, and preservation projects. The MAMC’s mission is focused on fostering growth, tackling complex manufacturing challenges, and pushing the boundaries of what's possible.

The challenge: Conventional 3D measurement tech compromises innovation and efficiency

The MAMC team has always been driven by one goal: achieving the highest level of accuracy in every project, whether it is fine-tuning a product’s design or creating prototypes for production.

As the center assessed a technology upgrade, it determined that new scanning tools would need to provide crystal-clear 3D measurements of complex objects, ensuring that every detail was recorded for design, replication, or analysis. Beyond that, the MAMC is also focused on supporting prototyping and manufacturing, ensuring that the measurements are integrated into production workflows. As a center that often works with historical artifacts and industrial components, accuracy in documentation and preservation was crucial.

Time is always a factor. The MAMC needs to count on ultra-fast techniques and technologies that can gather 3D data quickly, especially when working with large or immovable objects. In addition, because the MAMC prides itself on offering customized solutions to its clients, data reliability and repeatability are key.

Nevertheless, traditional 3D measurement methods became slow over time; they just didn’t provide the level of accuracy the team and its clients needed. Measuring by hand was time-consuming and sometimes prone to errors, especially when trying to reach tight or complex areas. The process was even slower when creating digital records for things like 3D printing, requiring a lot of post-processing to generate high-quality, usable 3D data.

The biggest concern was the accuracy of 3D measurements. Team members understood that if the data wasn’t precise, it could disrupt entire projects. This could lead to longer timelines, the need for rework, increased costs, customer dissatisfaction, and even lost business. In some cases, it could be even worse—damaging an irreplaceable item during the 3D measurement process. The MAMC MAMC wouldn’t allow this possibility to occur.

The overriding need reached a critical mass when staff members were asked to capture the 3D measurements of the famous 12-plus-foot, stainless steel Mothman statue in Point Pleasant. Without detailed drawings to work from, the team had to create a highly accurate digital model to replicate the statue. However, traditional measurement methods were no match for the complexity and scale of the project.

It was at that moment the MAMC knew it had to find a better solution.

“When we began searching for a new solution, our top priorities were accuracy and precision, particularly in capturing fine shapes and large objects," said Morgan Smith, Design Engineer at MAMC. "We needed a portable device that could access hard-to-reach places without sacrificing data quality. Speed was also a key factor, as we aimed to cut down scanning time for larger items. The solution had to be user-friendly and lightweight to reduce operators’ physical strain. We wanted an all-in-one product that would be interoperable with our existing workflows, including 3D printing and data processing, to minimize the need for extensive post-processing."

The solution: Creaform’s integrated 3D scanner and Scan-to-CAD software

After exploring several 3D measurement solutions on the market, the MAMC decided to invest in Creaform’s metrology-grade equipment, namely the HandySCAN BLACK™|Elite 3D scanner and integrated Scan-to-CAD software module, the easiest-to-use reverse engineering toolkit for feature extraction.

"The key factors that led us to choose the Creaform 3D measurement solution were its exceptional accuracy and versatility," Morgan explained. "Its ability to 3D scan intricate characteristics with an accuracy down to 0.025 mm was a game-changer for our projects. The speed of measurement also stood out; we were impressed by how it could reduce scanning time compared to traditional methods.”

Morgan also noted other criteria that sealed the deal when it came to Creaform. “We could see how the 3D scanner’s portability, lightweight design, and ability to generate models of complicated geometries could unlock new opportunities for us. And its compatibility with 3D printing truly the best fit for our needs."

Getting Creaform’s 3D measurement technology up and running was smooth for the team. The setup was quick, and the 3D scanner was simple to use right from the start. With Creaform’s comprehensive training and support, the MAMC team was capturing detailed 3D data in no time.

“The hands-on training helped everyone get comfortable, and Creaform’s support team was quick to jump in and help whenever we had questions. Within a few days, most users felt totally at ease with the technology and were ready to use it on their own,” Morgan said.