Ghost Dance is a research project out of Lusófona University that sets out to explore the value of human connection and how it can be recreated with a virtual dance partner. Project directors Cecilia de Lima and Rui Antunes looked to inertial motion capture to create fluid motions that real-life dancers could perform alongside. Challenge: The Ghost Dance team needed to build a 3D model based on dancers' movements to test the relationship between virtual and real-life performers. Creating a realistic model posed a significant challenge. Solution: Inertial motion capture technology allowed dancers to record an entire routine with maximum comfort and accuracy. The result was a virtual partner with smooth motions, making for a natural performance with its real-life counterpart.Key takeaways <ul><li>A diverse range of motion: Even complex movements in contemporary dance can be tracked with inertial sensors</li><li>Efficient recording: Entire choreographed performances were recorded quickly, to work around time restrictions in the dance studio</li><li>Comfortable wear: Dancers could perform unobstructed thanks to the adjustable nature of Xsens wearable technology</li><li>Fluid results: The virtual dance partner moved smoothly, creating a high sense of realism during the performance</li></ul>Studying the importance of human touchBefore beginning the project, the <a href="https://ghostdance.ulusofona.pt/outcomes/publications" target="_blank" rel="noopener noreferrer">Ghost Dance</a> directors had two main goals. “The first was to understand the need for physical, bodily presence between humans,” says Rui Antunes, Director. “In the new era of technology, we seem to be growing further apart, and we wanted to see whether this had an impact on our wellbeing.” To explore this, the team planned to use VR goggles to compare dancing with a human partner and a virtual counterpart. “We wanted to find out what happens when a human body interacts with a virtual entity,” explains Cecilia de Lima, Director. “We knew it would make for a completely different experience, but we needed to find out how and why.” The other part of Cecilia and Rui’s project was to see if virtual dance partners could improve via machine learning. The digital counterparts were created from the dancer’s movements, but they wanted to see if they could develop their own routines based on the information provided.To achieve these goals, extensive planning was put into place to find the right technology.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742888563673-Ghost+dance+Performance+Dancing+a+duet+with+avatar+2.jpg" style="width:100%px" class="fr-fic fr-dib" />Building a virtual dance partner This complex project required not only a skilled team, but a set of specialized technology to record the dancers’ performances and transform them into a digital counterpart.Dancers use movements that aren’t typical in day-to-day life, so it was crucial to have a motion capture system to accommodate that complexity. “The Xsens system could accurately record their movements for a perfect translation into a 3D model,” says Rui. Inertial sensors contain accelerometers and gyroscopes, tracking the joint rotation and velocity of the subject. This pinpoint precision allowed for lifelike movements in the virtual dance partner, making a more natural experience for the real-life dancers.“Comfort is essential when dancing,” explains Cecilia. “We needed the motion capture technology to be unobtrusive to get the best results.” The system consists of 17 sensors, which all strap individually onto the body, making each one adjustable to the wearer’s preferences. Having this comfort led to more natural, fluid moves to create the virtual partner. <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742888595821-Ghost+dance+Motion+Capture+for+Avatar+Dance+duets+7.jpg" style="width:100%px" class="fr-fic fr-dib" />Machine learning for virtual dance partnersAfter the dancers were recorded and the virtual partners were made, Cecilia and Rui needed to see whether they could develop from the base-level data. To do this, they created machine-learning algorithms to put the models to the test.A machine cannot make subjective decisions, so the team found a solution to objectify and quantify the dancers’ movements. “The eight Laban efforts are commonly used in theatre and dance classes to expand students’ creativity,” says Cecilia. “These are basic movements, including punching, wringing, and pressing, that a robot could easily identify.”From this information, Cecilia and Rui hope to develop a virtual dance partner that can make its own organic moves in time with a real-life dancer. “Inertial motion capture was the perfect choice for this type of research,” continues Rui. “We had a well-built model that was based on real movement, which provided a baseline for machine learning.”“The research project was incredibly enlightening on the importance of human connection,” concludes Cecilia. “Virtual dance partners are not currently able to replace real ones.” Small sensations, such as breaths and footsteps, are vital when dancing cohesively with a partner. At this stage of technology development, these nuances are not available digitally. However, that’s not to say it won’t happen in the future. Ghost Dance proved that in the future, this could be a feasible alternative to dancing with a real counterpart. It seems increasingly possible when using inertial motion capture to create the basis of the digital partner.Using Xsens meant that the dancers could perform freely, with no need to adjust choreography. This led to an optimal experience when dancing with a virtual partner. <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742888642787-Ghost+dance+Overlay+of+virtual+and+real+partners+dancing+3.png" style="width:100%px" class="fr-fic fr-dib" />

With Inertial Motion Capture

Ghost Dance: Building a virtual dance partner

<html><head></head><body>ChallengeFilmmakers Sam and Andy needed convincing animations that fit into a sci-fi narrative. And they needed to create those movements efficiently and authentically.SolutionAn easy-to-use mocap system that delivered high-quality data, capturing the quirks and nuances of the actors, and gave the animation team plenty of references to work with.Key takeaways<ul><li id="isPasted">Inertial motion capture: More freedom to shoot anywhere and no need for a dedicated mocap studio.</li><li>Ease of use:&nbsp;Xsens is a simple tool for <a href="https://www.movella.com/products/motion-capture" target="_blank" rel="noopener noreferrer">motion capture</a>, even without a VFX supervisor on hand.&nbsp;</li><li>Perfect for film production:&nbsp;Put on the suit, make the movements, visualize the data. Small changes could be made quickly and with high precision.</li></ul>Set in a future where humanity is long extinct and the Earth is thawing from a nuclear winter, Love Me is a sci-fi arthouse film created by Sam and Andy Zuchero in which two artificial intelligences, a buoy and a satellite, fall in love. Played by Oscar-nominated <a href="https://www.imdb.com/name/nm0829576/" target="_blank" rel="noopener noreferrer">Kristen Stewart</a> and <a href="https://www.imdb.com/name/nm3081796/?ref_=nv_sr_srsg_0_tt_0_nm_8_in_0_q_steven%2520yeun" target="_blank" rel="noopener noreferrer">Steven Yeun</a>, the machines slowly evolve into sentient beings, with the audience able to see the transformation before their very eyes.WatchLove Me Featurette, featuring Xsens mocap:<iframe width="640" height="360" src="https://www.youtube.com/embed/deVnCSQWDnI?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;</iframe>Preparing for a nuclear winterIn Love Me, a buoy and satellite cross paths and begin communicating. The pair use the Internet to examine what human life was like before the fallout – and end up emulating a popular vlogger duo by creating avatars and eventually morphing to humanlike stature. Creating the three phases required a complex and detailed filmmaking process.Sam and Andy Zuchero were responsible for almost all aspects of the film’s creation, from writing to direction to production, with the help of a dedicated team. A task of this size is no mean feat, especially when extensive VFX is involved. The first step in the production process was to film the native shots, to later be transformed into a post-apocalyptic landscape through VFX.The camera crew set out across North America to find the perfect locations. “We shot the prop buoy and satellite with real props, to give a realistic, gritty feel to our characters,” explains Sam. “And the first scenes with Kristen and Steven were shot using motion capture at the end of 2021.”Xsens in sci-fi filmsBefore production, Sam and Andy researched the best type of motion capture for Love Me, prioritizing efficiency without compromising on quality. “We realized that optical motion capture would be too obstructive, so the <a href="https://www.movella.com/products/motion-capture/xsens-mvn-link" target="_blank" rel="noopener noreferrer">Xsens system</a> was the best option,” Sam explains.&nbsp;Xsens technology uses inertial technology that logs joint rotation, velocity, and position on the body. These are simply put on as a suit or multiple wearables and their data is instantly sent to processing software – no cameras needed. Traditional optical motion capture requires a large setup with good lighting, a dotted suit, and multiple cameras to film the subject, which wasn’t ideal for the intimacy required in Sam and Andy’s production.“Using this type of motion capture means that the audience can see every quirk and tiny movement of the actor,” Andy explains. Even when the actors aren’t completely recognizable visually, viewers should be able to pick up on their body language.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742207403473-Love+Me+%28BTS%29+2.jpg" style="width: 100%px;" class="fr-fic fr-dib">Small studio, big ideasThe finished film was released by Bleecker Street in 2025 after an initial screening at the Sundance Festival in January 2024. Sam, Andy, and the Love Me production team successfully blended the two genres of romance and sci-fi, thanks in no small part to the help of Xsens motion capture technology providing an unobtrusive solution.“From an actor’s point of view, it was amazing to include the actor’s intentions and have them translate even through animation,” Sam concludes. “You turn on the motion capture equipment and they can perform, without waiting for the correct lighting and camera setup.”&nbsp;“We really appreciated how simple it was to realize our ideas using Xsens,” Andy says. Using this technology provided the team with an impressive finish to the film that shares the same quality as major Hollywood features, with a fraction of the time spent.</body></html>

With Xsens motion capture technology

Love Me: a sci-fi film production

The exploitation of renewable power sources is an essential response to the climate crisis. Solar and wind energy are the giants of the renewable world, but their output is unpredictable and intermittent. From one week to the next, it is difficult to forecast reliably how strongly the wind will blow or how brightly the sun will shine. This is a problem for national electricity grid operators, which are responsible for dynamically balancing the energy supply with the load.&nbsp;There is, though, a renewable energy source which is naturally very predictable: tidal power. The relative distances and positions of the sun, moon and Earth all affect the size and magnitude of the Earth’s two tidal bulges. At a local level, the magnitude of tides is influenced by the shape of the shoreline, as well as by weather conditions. Because the tides are driven by planetary movement, their timing can be precisely predicted, enabling power system operators to plan confidently for a tidal power generator’s contribution to the grid.&nbsp;This helps explain the growing interest in Orbital Marine Power, a UK-based innovator in tidal power generation. Succeeding where many tidal turbine manufacturers have failed, Orbital has developed a unique floating structure with turbines on each of two retractable legs. Its system off the coast of Orkney in Scotland generates a nominal 2MW output which helps the UK’s national grid to reduce its reliance on fossil fuel power sources.&nbsp;The north Atlantic is an unforgiving operating environment for electrical and electronics systems, however – and this is why Orbital relies on a robust <a href="https://www.movella.com/products/sensor-modules" target="_blank" rel="noopener noreferrer">Xsens MTi </a>inertial motion sensor to keep the floating turbine structure stable. &nbsp;The <a href="https://www.movella.com/products/sensor-modules" target="_blank" rel="noopener noreferrer">MTi motion sensor</a> is incorporated in the system as part of a Gable IMU (Inertial Measurement Unit) from Gable Technologies, which created an EtherCAT interface to integrate Xsens sensors seamlessly into industrial applications such as Orbital’s tidal power generator. This combination takes advantage of the accuracy of Xsens sensors, ensuring reliable performance in even the harshest conditions.Free from the seabed: the key Orbital innovationThe breakthrough that the Orbital design team made came from its observation of previous attempts to fix tidal turbines to the seabed: many companies that adopted this approach ran out of money, strained by the massive cost of hiring construction vessels and building a fixed underwater structure.&nbsp;The floating structure of the Orbital O2 generator eliminates these construction costs, and uses a simpler mooring system to hold the hull in place. On each side of the hull is a retracting leg featuring a turbine: this part of the structure can be lowered to the depth at which the most energetic tidal flows are to be found, or raised to protect the structure when extreme weather is forecast. &nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740729489392-Picture1.jpg" style="width: 100%px;" class="fr-fic fr-dib">For the turbines to work effectively, the structure needs to be stable both in its geoposition, and in its attitude: excessive movement – roll or pitch – reduces the flow through the turbines, and thus affects total power output. It must maintain this stable position in extremely challenging conditions: floating in a narrow channel between islands, where the tidal flows are particularly strong, the Orbital hull is exposed to wind, saves, salt water ingress, and sunlight.&nbsp;Stable station keeping– maintaining a fixed position and attitude – in all conditions calls for an array of sensors, including a Doppler sensor to measure the speed of the tidal flow, load gauges on both legs, a GPS satellite sensor for geopositioning, and various weather sensors such as anemometers.&nbsp;Alongside these, the job of continuously measuring the hull’s pitch and roll, as well as low-frequency vibration, is performed by an Xsens MTi motion sensor. MTi sensors’ accuracy and performance are renowned – these devices are used in many applications which measure motion with millimetre precision, more than enough for the Orbital application.&nbsp;Angel Rua Santaclara, Orbital’s Powertrain Manager, was convinced that the performance of the MTi sensor would meet the tidal power generator’s needs, backed by the comprehensive magnetic calibration capability provided in the MT Software Suite from Movella. &nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740729511338-Picture2.jpg" style="width: 100%px;" class="fr-fic fr-dib">But he says that equally important was the sensor’s ability to operate reliably in the harsh marine environment. He says: ‘The interior of the hull is dry by design – this facilitates repair and maintenance. But inevitably a floating marine structure is always going to be exposed to salt water and a humid atmosphere, and so every electrical and electronic component we use has to be rigorously specified to withstand these harsh conditions.&nbsp;‘That’s why Orbital’s first instinct was to use the specialist motion sensors that are marketed to the oil and gas industry for use in rigs and drilling platforms. But we found that they are over-specified for our requirements – for instance, they can handle operation at great depths. That meant they were also hugely expensive. We were glad to discover the <a href="https://www.movella.com/products/sensor-modules" target="_blank" rel="noopener noreferrer">MTi motion sensor</a> family, because it gives us the performance we need. The Gable IMU has an IP67-rated enclosure, which means that it can survive the damp atmosphere in the generator and repeated contact with salt water. The sensor has operated reliably ever since it was installed in our generator off the coast of Orkney.’Promising future for tidal power generationAngel Rua Santaclara says that having proved the feasibility of tidal power generation with the installation of the O2, the company is preparing to scale up its operation, building more generators for use in UK waters and elsewhere. He says, ‘Tidal power has its part to play in a carbon-free future for the electricity grid, and it can be deployed anywhere that has strong tidal flows. Our design, including the sensor systems for controlling the motion of the hull, is now proven, and we are looking forward to offering our design all around the world.’&nbsp;

Helping Maintain Stable Position in Fast-Moving Waters

Orbital's Breakthrough Design for Tidal Power Generator Using Xsens Technology

Toshiba Hydro Power (Hangzhou) Co., Ltd (THPC), a joint-venture between Japan’s Toshiba and China’s Power Construction Corporation, is now seeking new technology “3D scanning” to ensure high quality of its manufactured hydropower equipment and provides cutting-edge products to customers worldwide.The company, long been involved in hydropower industry, is committed to developing new technologies and offering advanced products, specially in the design, development and manufacturing of hydropower equipment.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740720601913-1.jpg" style="width: 100%px;" class="fr-fic fr-dib">Hydropower is a renewable and clean source of energy that can offer various advantages to the society and the environment. It can reduce dependence on fossil fuels and enhance energy security. Therefore, improving the quality of hydropower equipment can help to maximize the benefits of this renewable energy source.The hydropower industry is undergoing rapid growth, and the large-scale equipment used in this industry requires huge investments and high maintenance costs. It is important for hydropower equipment manufacturers to enhance product reliability from the design to the manufacturing to reduce costs and improve efficiency.&nbsp;Mr. Sato from the leading company Toshiba Hydro Power (Hangzhou) Co., Ltd shared with us how they collaborated with Scantech to leverage 3D scanning to enhance inspection.&nbsp; <h2 id="isPasted">Hydropower Equipment Manufacturer&nbsp;Seek to&nbsp;Improve Its&nbsp;Parts</h2>Hydropower equipment consists of large and complex components that are affected by various factors during production and operation. These factors include vibration, humidity, temperature, acid and alkali corrosion, etc. High-quality components can ensure the performance and lifespan of the equipment, as well as the efficient and stable operation of the hydropower unit. This way, the hydropower equipment manufacturers can optimize their benefits.&nbsp;The manufacturer in this story is seeking to develop more advanced equipment to achieve higher capacity, speed and efficiency.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740720639107-2.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">How a 3D Scanner Helps to Inspect Hydropower Equipment</h2>Traditional measurement methods have some shortcomings such as low efficiency, high personnel requirements, and being time-consuming. Moreover, these methods cannot generate intuitive reports or provide complete measurement data for further analysis. The lack of data means that these methods cannot provide comprehensive guidance for subsequent maintenance and repair. It is because operators and engineers cannot predict or evaluate the operating conditions of the equipment without complete measurement data.&nbsp;High-tech 3D scanning offers more diverse solutions for hydropower equipment manufacturers from product design, production to even maintenance. By using TrackScan-Sharp, the advanced optical 3D laser scanner from Scantech, operators can conduct NDT testings of equipment to ensure the quality of equipment. High quality helps to extend the service life of hydropower systems, reduce losses and improve the efficiency.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740720656882-3.jpg" style="width: 100%px;" class="fr-fic fr-dib">Mr. Sato expressed his thoughts on using TrackScan-Sharp, “The TrackScan-Sharp can obtain 3D data of parts quickly with optical tracking, and no targets are needed. I am impressed by its 6-m tracking distance. It is really good when compared to common optical tracking systems. As its working volume is large, operators do not need to move the tracker frequently to scan the whole part.&nbsp;It is lightweight and portable, which can be set up easily on the site. The working conditions in a factory is usually harsh. TrackScan-Sharp’s footprint is small, and it is highly adaptive to harsh environmental conditions. It can be used on site to fulfill tasks.&nbsp;TrackScan-Sharp can meet our needs for quality control and help us deliver high-quality products faster to our customers.”&nbsp;&nbsp;<h2>Advantages&nbsp;of Optical 3D Scanning System&nbsp;</h2>Free&nbsp;and wide-range measurements&nbsp;The optical tracking system features a 25-MP industrial camera and a 49-m³ tracking volume, delivering high-resolution and wide-range measurements. It can capture data from long distances in a wide range without the need to move the tracker frequently. This makes it ideal for measuring large parts such as: large hydraulic turbine blades, runner of pumped storage unit, generator wire rods, and more.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740720689806-4.jpg" style="width: 100%px;" class="fr-fic fr-dib">High-precision measurements for various scenarios&nbsp;The system combines advanced hardware and robust algorithm to deliver high-precision measurements for various tracking ranges: 0.049-mm volumetric accuracy for 10.4 m³ small-range tracking, 0.067-mm volumetric accuracy for 28.6m³ medium-range tracking, and 0.089-mm volumetric accuracy for 49.0m³ large-range tracking. It can easily capture the fine details of various medium and large components of hydropower equipment.&nbsp;Advanced and efficient 3D scanning&nbsp;TrackScan-Sharp can scan the entire part without requiring any targets, saving time for sticking and removing them. It also allows scanning multiple part simultaneously, enhancing the measurement efficiency.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740720704567-5.jpg" style="width: 100%px;" class="fr-fic fr-dib">Real-time&nbsp;inspection&nbsp;reportsTrackScan-Sharp features powerful 3D software that can capture, analyze and store data in real time. It can scan the components of hydropower equipment and process the point clouds to generate color maps. It can also store the 3D data in the database for further archiving. TrackScan-Sharp offers precise assessment of the part conditions to deliver high-quality products.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740720750676-6.jpg" style="width: 100%px;" class="fr-fic fr-dib">SCANTECH’s 3D scanners and 3D solutions are widely applied in the field of energy engineering, such as inspection of hydraulic turbine guide vane, turbine casting, oil and gas pipeline, wind power flange, etc. It helps many large-scale energy enterprises to achieve digital transformation and upgrading.

This video shows how Toshiba Hydro Power (Hangzhou) Co., Ltd, a leading hydropower equipment manufacturer, improves inspection workflows with SCANTECH’s optical 3D measurement system TrackScan-Sharp. Learn more.

SCANTECH 3D Scanner Helps Toshiba Hydro Power to Inspect

In the ever-evolving world of <a href="https://www.3d-scantech.com/3d-scanners/" target="_blank">3D scanning</a>, Digitize Designs, in collaboration with Scantech, undertook the impressive task of digitizing a retired Cobra helicopter. This case study exemplifies how real-world objects can be meticulously transformed into digital models, showcasing the remarkable capabilities of the NimbleTrack 3D scanning system, a completely wireless and portable solution.<h2>Challenges of 3D Scanning a Helicopter&nbsp;</h2>3D scanning a retired Cobra helicopter presents several unique challenges due to its size, shape, structure, and materials. Here are some key considerations:<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739930364771-1.jpg" style="width: 100%px;" class="fr-fic fr-dib">Complex Geometry:&nbsp;The helicopter’s intricate design, including its rotors, tail boom, and mechanical parts, demands high-precision scanning to capture fine details accurately.Accessibility: Some parts of the helicopter may be difficult to access, requiring specialized techniques to ensure comprehensive coverage.Varied Textures: Different materials (e.g., metal, glass) used in the helicopter’s construction can pose challenges in achieving uniform scan quality.<h2 id="isPasted">Introduction to Scantech NimbleTrack</h2>The Scantech <a href="https://www.3d-scantech.com/product/nimbletrack-wireless-3d-scanning-system/" target="_blank">NimbleTrack is an advanced wireless 3D scanning system</a> designed to capture high-precision 3D data of physical objects. Its portability and ease of use make it ideal for various applications, from industrial inspections to heritage preservation. It is capable of capturing 3D data of different parts, intricate surfaces, and complex structures with ease. The system's wireless functionality allows for unprecedented flexibility, enabling users to scan objects from any angle, even from challenging positions.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739930535425-2.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">3D&nbsp;Scanning&nbsp;a Helicopter&nbsp;</h2>The digitization process began with setting up the NimbleTrack system outdoors at the site where the Cobra helicopter was stationed. NimbleTrack’s wireless and portable 3D scanning simplified the scanning process, even at elevated positions, including atop a six-foot ladder.As the scanning commenced, the NimbleTrack showcased its ability to handle the helicopter's intricate free-form shapes and complex structures, such as pipes and tubes. The scanner's high resolution and accuracy ensured that every detail, no matter how small, was captured. This level of precision is crucial for applications requiring detailed replicas or models for further analysis.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739930556505-3.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Advantages of NimbleTrack Optical 3D Measurement System&nbsp;</h2>Wireless Freedom:&nbsp;The NimbleTrack system is fully wireless, eliminating the need for cables to power the instrument or transfer data. This feature allows for on-site measurements even in the absence of a power supply.Compact and Portable:&nbsp;With a length of 57 cm and a total weight of 2.2 kg for the tracker, and 1.3 kg for the scanner, NimbleTrack is lightweight and easy to carry and operate. Therefore, the engineer can capture data from hard-to-reach areas.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739930572044-4.jpg" style="width: 100%px;" class="fr-fic fr-dib">High Frame Rate:&nbsp;The system operates at a high frame rate of 120 FPS, ensuring fast and smooth scanning experiences.Target-Free Scanning:&nbsp;NimbleTrack does not require targets for scanning, streamlining the measurement process.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739930584478-5.jpg" style="width: 100%px;" class="fr-fic fr-dib">Industrial-Grade Precision:&nbsp;The system achieves an accuracy of up to 0.025 mm and a maximum volumetric accuracy of 0.064 mm. It is capable of capturing intricate details of different parts with ease.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739930594065-6.jpg" style="width: 100%px;" class="fr-fic fr-dib">Robust Performance:&nbsp;Equipped with powerful algorithm, NimbleTrack delivers efficient and reliable measurement experiences. It excels at capturing data from different surfaces.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739930604879-7.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Scan-to-CAD Model&nbsp;</h2>Following the scanning process, the data was processed using 3D software designed for converting scan data into 3D CAD models. The data processing workflow included:Importing Scan Data:&nbsp;-The scanned data&nbsp;was imported into 3D software.Cleaning and Refining:&nbsp;-Noise and unnecessary data points are removed from the point cloud.-This step ensures a cleaner and more accurate representation of the scanned object.Mesh Generation:&nbsp;-The refined point cloud was converted into a mesh model.-Meshes are essential for creating detailed digital models.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739930623564-8.jpg" style="width: 100%px;" class="fr-fic fr-dib">Solid Model Creation:-Using the mesh model, a solid CAD model is generated.-The solid model represents the object as a complete, editable 3D structure.-It serves as a foundation for further design, analysis, or manufacturing processes.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739930634736-9.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Applications of 3D Scanning&nbsp;</h2>3D scanning can contribute to various aspects from product development to <a href="https://www.3d-scantech.com/applications/aerospace/" target="_blank">maintenance, repair, and overhaul (MRO) of airplanes and helicopters</a>.&nbsp;Product Development&nbsp;Advanced 3D scanning captures accurate data of aircraft components, allowing manufacturers to create rapid prototypes for testing and validation. It can also help recreate legacy parts or design new ones by capturing precise 3D models. Besides that, 3D scanners can verify structural deformations, optimizing designs during research and development processes.Inspection3D scanning captures millions of data to inspect intricate components like turbines and engines. Non-contact measurement ensures accuracy without compromising delicate surfaces. For example, Scantech’s handheld 3D laser scanners excel at inspecting sub-flush conditions of fasteners installed on airplane exteriors. These fasteners withstand extreme stress and are crucial for aircraft assembly.MROIn-service aircraft are scanned to identify hidden errors, deformations, and defects. 3D measurement technology ensures proper operation and passenger safety. Handheld 3D scanners provide non-contact measurements without damaging aircraft parts. By scanning the entire surface of an aircraft, including complex geometries, technicians can identify structural issues, corrosion, or fatigue cracks. The high precision of 3D scans allows for early detection of problems, minimizing downtime and reducing the risk of in-flight failures.<h2>Conclusion</h2>The digitization of the Cobra helicopter demonstrated the capabilities of the Scantech NimbleTrack system in transforming a complex real-world object into a detailed digital model. The portability and wireless functionality of the NimbleTrack, combined with the powerful data processing tools in 3D software, showcased a seamless workflow from scanning to model creation.This case study underscores the revolutionary impact of 3D scanning technology in various fields. The ability to capture intricate details and convert them into accurate digital models opens up numerous possibilities, from preserving historical artifacts to enhancing industrial design and manufacturing processes.Discover the magic in action: Watch the <a href="https://www.youtube.com/watch?v=h7OOP-PnqHQ" target="_blank">webinar highlights</a> and explore the capabilities of the Scantech NimbleTrack system further.&nbsp;

SCANTECH and Digitize Designs collaborated to digitize a retired Cobra helicopter, showcasing the NimbleTrack 3D scanning system. The resulting scan data was transformed into 3D CAD models, demonstrating its applications in product development, inspection, and maintenance. 

Digitizing a Cobra Helicopter with NimbleTrack to Unlock 3D Scanning Potential

With the majority of spine surgeons experiencing bodily discomfort due to their work, the need for ergonomic improvements in the healthcare industry is clear. Orthopedic spine surgeon Philip Louie is on a mission to address this issue, leveraging&nbsp;<a href="https://www.movella.com/products/motion-capture" target="_blank" rel="noopener noreferrer">Xsens motion capture</a>&nbsp;technology and Scalefit software to identify pain points and create solutions that enhance surgeons’ physical well-being and long-term performance.Challenge:&nbsp;To effectively analyze surgeons’ occupational health and safety, healthcare professional Philip Louie needed an objective dataset to define specific problem areas.Solution:&nbsp;Using the Xsens inertial motion capture and <a href="https://www.movella.com/integrations/scalefit" target="_blank" rel="noopener noreferrer">Scalefit&nbsp;</a>software provided highly accurate data on the surgeons’ movements, all while maintaining privacy for themselves and their patients.Key takeaways:<ul><li id="isPasted" style="font-weight: bold;">Advanced data accuracy for ergonomic assessment: inertial motion capture records even the smallest movements, ensuring precise analysis</li><li style="font-weight: bold;">Ensuring privacy: Camera-less technology guarantees anonymity for both patients and surgeons</li><li>Authentic movement thanks to unobtrusive technology: comfortable wearables allow ergonomic professionals to track real, natural motion</li></ul>An overwhelming 80% of spine surgeons experience bodily discomfort. This high proportion shows a need for occupational health and safety to be prioritized within the healthcare industry. Such injuries can lead to unexpected time off, declining performance, or even early retirement. <a href="https://www.linkedin.com/in/philip-louie-1605807/" target="_blank" rel="noopener noreferrer">Orthopedic spine surgeon Philip Louie</a> is conducting a study to find out how to improve surgeons’ physical well-being to make their highly technical job that little bit easier.Stopping spine surgeon injuries“The majority of healthcare professionals experience some sort of bodily discomfort due to their job,” explains Philip. “So the first part of our study was to find the physical pain points of spine surgeons.” After completing a series of intense surgeries, Philip noticed the harmful impact and the role it had on his joints and muscles.However, Philip was not the only surgeon experiencing these issues. He started the study to show that physical well-being is a profession-wide issue, not just a personal one, and with this information, hopes to build more ergonomically friendly surgery rooms. To effectively demonstrate his point, he needed objective data that put a spotlight on the exact areas for improvement in the healthcare industry.Preparing for researchPhilip decided to perform ergonomic analyses on three surgeons, each performing the same procedure ten times. “Using replicable surgeries as the basis for the study was crucial,” he says. “It allowed us to compare and contrast each dataset to identify outlying issues.” Philip then researched the different techniques for assessing occupational health and safety.“For the first attempt, we used the REBA method,” explains Philip. REBA (rapid entire body analysis) requires an ergonomics analyst to manually assess the worker’s movements, using their knowledge of physical well-being to point out issues and suggest amendments. “We found that while this was useful, we didn’t have the quantitative, set-in-stone data needed for this project.”&nbsp;An extra person in the surgery room also led to privacy issues for both patient and surgeon. Most would be uncomfortable having their work, or personal procedures, observed by a third party. Filming would also create an anonymity issue, leading to faces having to be blurred and time taken away from the investigation. After extensive research, Philip found the answer to anonymity while further improving the quality of data.Using Xsens and Scalefit technology“When we found inertial motion capture, we knew that it was the only way to efficiently carry out our research without encroaching on the privacy of others,” says Philip. Using inertial technology, the Xsens motion capture system tracks velocity, acceleration, and rotation without requiring any cameras. Instead, the data is sent directly from the wearables to post-processing software.“I was able to perform a two-hour surgery while wearing the Xsens system,” Philip continues. “By the end, myself and the other surgeons forgot we were even wearing it.” The Awinda set contains 17 wireless sensors, all individually strapped to the body for bespoke comfort. The team could also maintain a sterile environment, with the sensors tucked underneath scrubs.Using the Xsens motion data and Scalefit software, Philip could effectively collate his results to show objective findings, pinpointing the need for ergonomic improvement in the surgery room. The research team quantified this data to highlight the specific areas of a surgeon’s body that were most affected by their job. Having this abundance of data instantly available for research was essential for rapidly progressing the project.Looking aheadErgonomic analysis is best carried out in a worker’s natural environment, doing the tasks they would do every day, and Xsens allows you to do just that. “I hope to roll out this technique to the rest of the healthcare industry,” says Philip. “Its usefulness was invaluable to us, and it can help many other professionals perform their jobs more safely.”Philip’s research project is drawing to a close, and the last rounds of motion capture data are being recorded. He hopes to create tangible solutions for spine surgeons, with his ability to identify exact pain points and put together a plan to prevent them from happening, such as full-body exercises to relieve tension from the back, shoulders, wrists, and other vulnerable joints.&nbsp;Just wearing the Xsens suit raised awareness for the toll surgery takes on medical professionals. Philip could see in real time how his body was reacting to holding it in a fixed position, encouraging him to relax and avoid experiencing unnecessary pain.“Inertial motion capture technology was the only solution for this project,” concludes Philip. “Having this quantitative data is invaluable to our occupational health and safety.

With Xsens MVN Analyze

Ergonomic analysis for spine surgeons: saving your back and neck

In the realm of extreme sports, few events rival the intensity and challenge of the Dakar Rally. Beyond being a mere race, it stands as a testament to human endurance and the resilience of machinery. Originating in 1978, the Dakar Rally has grown into a global phenomenon, spanning over 5,000 miles of unforgiving terrain, from deserts to mountains and savannas.<iframe width="640" height="360" src="https://www.youtube.com/embed/pM_aDHaCfq8?&amp;t&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> Prodrive made its debut in the rally scene in 2020 and has since been a consistent participant in the last three Dakar rallies. They have earned a well-deserved reputation for their adeptness in designing and manufacturing resilient and high-performing race and rally cars. Their track record of success speaks volumes about their proficiency in creating championship-worthy vehicles. A prime example of their prowess is when the Prodrive's Hunter model clinched the top three positions on a Dakar stage, highlighting the company's dedication to engineering excellence.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736821800131-768.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">“We need to monitor the health of our vehicles, particularly the space frames”-Paul Doe, Chief Chassis Engineer.&nbsp;</h2>The Dakar Rally stands out as one of the toughest races worldwide, with its challenging terrains and extreme weather conditions. Ensuring the structural integrity of vehicles is paramount to ensure the safety of drivers and co-drivers. Any damage or abnormalities in the frame could jeopardize the vehicle's stability, rendering it unsafe for use.The vehicle's frame serves as the foundation of its structure, influencing its overall performance. Compromised frames can impact handling, speed, and reliability – crucial factors in the demanding environment of the Dakar Rally. Regular inspections play a vital role in identifying potential issues early on, allowing for prompt repairs and maintenance. This proactive approach extends the vehicle's lifespan and reduces the risk of unexpected breakdowns or malfunctions during the race.Post-rally inspections yield valuable insights into how vehicles have endured the rally's harsh conditions. These insights inform refinements and improvements in the design and manufacturing processes, driving continuous enhancement and innovation in 3D engineering solutions.The inspection process of the Dakar frame goes beyond a mere routine check; it is a comprehensive endeavor that underscores safety, enhances performance, promotes longevity, and fuels the relentless pursuit of excellence in motorsport.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736821306934-3.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Elevating the Frame 3D Data Capturing Process with TrackScan-Sharp</h2>For this task, our local partner utilized the Trackscan-Sharp, a state-of-the-art large-scale 3D scanner, renowned for its advanced capabilities:1. This tracking 3D scanning system harnesses cutting-edge optical tracking technology and high-resolution cameras to deliver unmatched accuracy and efficiency in scanning large-scale parts and components.2. With a measuring volume of 49m3 and a tracking distance of up to 8 meters, the Trackscan-Sharp enabled capturing the front and sides of the vehicle in a single position, minimizing the need for tracker repositioning and thus saving time while reducing the risk of errors.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736821328358-2.jpg" style="width: 100%px;" class="fr-fic fr-dib">The following step involved a comprehensive inspection of the motorsport frame. By comparing the latest scan data with historical records, any structural changes or potential damage were identified. Importing the STL file representing the newly captured 3D mesh of the automotive frame into inspection software facilitated a side-by-side comparison with existing records. This critical analysis allowed for the detection of any deviations or changes in the frame's structure resulting from the stresses endured during the rally.<h2>Conclusion</h2>The utilization of 3D scanning technology in the realm of motorsport, particularly in race car inspection, represents a significant advancement in efficiency and precision. The integration of cutting-edge tools like the TrackScan-Sharp has revolutionized the inspection process, offering a seamless and accurate experience for continuous improvement and innovation in race car design and manufacturing processes.&nbsp;

This blog introduces Prodrive's venture into the Dakar Rally highlights the critical role of 3D scanning technology in race car inspection. Leveraging TrackScan-Sharp, Prodrive ensures thorough assessments of vehicle frames, vital for maintaining safety and performance in extreme racing conditions.

Navigating Extreme Terrain: Prodrive's Utilization of 3D Scanning Tech in Motorsport

The aviation industry continually evolves, with ongoing efforts to refine and improve existing technologies. Within this vast landscape, the development of single-person flight carriers—such as gyrocopters—stands out as an exciting niche. These compact, lightweight aircraft offer unmatched freedom and mobility, captivating both hobbyists and seasoned pilots. As the industry evolves, so does the need for meticulous inspection and quality control to ensure these cutting-edge machines meet the highest standards of safety and performance.<h2>NIKI Rotor Gyrocopter Manufacturing Company</h2>NIKI Rotor Aviation, a Bulgarian company, specializes in producing gyrocopters which blend the best of airplanes and helicopters. Founded by an owner with a passion for aviation, NIKI Rotor began as a hobby in a small workshop, where miniature remote-controlled aircraft models took flight. Today, the company produces fully operational gyrocopters ready for sale.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736299275388-1.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">For Inspection and&nbsp;<a href="https://www.3d-scantech.com/solution/product-development/" target="_blank">Product Development</a>&nbsp;</h2>Finished Product Inspection:&nbsp;Utilize a 3D scanner to inspect the finished gyrocopter, ensuring it meets design specifications and quality standards. By capturing precise 3D models of the gyrocopters, dimensions, tolerances, and surface quality can be verified, ensuring the final product is defect-free.Product Development:&nbsp;Generate an accurate 3D model of the existing gyrocopter frame through <a href="https://www.3d-scantech.com/3d-scanners/" target="_blank">3D scanning</a> to extract geometric data for updating engineering drawings. The measurement assists in analyzing current designs and optimizing product structures.<h2>What Part To Be Inspected&nbsp;</h2>One of the primary components NIKI Rotor needs to 3D scan is a large, intricately designed frame of their gyrocopters. This frame, measuring approximately 2m x 1m x 3m, is made of black carbon fiber with a bright yellow paint finish. Its large curved surfaces add complexity to the measurement process, demanding a high level of accuracy and detail in measurement.<h2>Measurement Challenges&nbsp;</h2>Traditional measurement methods fall short when faced with such a complex and sizable component. The primary challenges include:<ul><li>&nbsp;High Precision Requirements:&nbsp;Ensuring flight safety necessitates high precision in the <a href="https://www.3d-scantech.com/solution/3d-inspection/" target="_blank">manufacturing and inspection&nbsp;</a>of gyrocopter parts, often at the micron level.</li><li>&nbsp;Wide Range of Sizes:&nbsp;Gyrocopter components vary significantly in size, from small precision parts to large structural components.</li><li>&nbsp;Complex Geometries:&nbsp;Gyrocopter components typically have intricate curves and geometric shapes, including rotor blades and fuselage structures.</li><li>&nbsp;Surface Characteristics:&nbsp;Carbon fiber, particularly in black, poses significant challenges for conventional scanning techniques.</li><li>Time-Consuming Processes:&nbsp;Traditional probe measurements are time-intensive, making them impractical for such large parts.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736299297367-2.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Scantech's 3D Solutions</h2>To address these challenges, NIKI Rotor turned to Scantech's Bulgaria&nbsp;reseller, Great Master, for&nbsp;cutting-edge 3D scanning technology, specifically the&nbsp;<a href="https://www.3d-scantech.com/product/trackscan-sharp/" target="_blank">TrackScan-Sharp&nbsp;optical 3D measurement&nbsp;system</a> to capture highly accurate and detailed 3D data. This system offers a range of features tailored to meet the demands of inspecting complex, large-scale parts.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736299308197-3.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Scanning Process</h2>The TrackScan-Sharp system employs advanced blue laser technology, which is particularly effective for scanning carbon fiber and black surfaces. The scanning process, which can be completed in approximately 10 minutes, involves the following steps:<ul><li>&nbsp;Setup: Positioning the TrackScan-Sharp to cover the entire component.</li><li>&nbsp;Scanning:&nbsp;Utilizing the blue laser to capture detailed measurements without the need for targets.</li><li>&nbsp;Data Collection: Gathering comprehensive data to create precise color maps.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736299257687-4.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Benefits of 3D Solutions</h2>The advantages of using Scantech's 3D solutions are manifold:<ul><li>&nbsp;Accuracy:&nbsp;TrackScan-Sharp can measure the dimensions and tolerances of gyrocopter components accurately with accuracy of up to 0.025 mm , ensuring they meet design specifications and quality standards. The blue laser technology ensures accurate scanning of carbon fiber and black surfaces.&nbsp;</li><li>&nbsp;Efficiency:&nbsp;The TrackScan-Sharp's large tracking volume allows for a complete scan in a single shot, significantly reducing inspection time.</li><li>&nbsp;Simplicity:&nbsp;The system's ability to scan without targets simplifies the process.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736299325825-5.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">For Inspection&nbsp;</h2><ul><li>&nbsp;Surface Quality Assessment:&nbsp;High-resolution scanning allows for detailed inspection of surface quality, identifying any defects or imperfections that may affect performance.</li><li>&nbsp;Data Clarity:&nbsp;The resulting comparison drawings clearly highlight discrepancies between the CAD model and the actual component, providing essential data for design corrections and improvements.</li></ul><h2>For Product Development&nbsp;</h2><ul><li>&nbsp;Accurate 3D Models:&nbsp;The system generates precise 3D models of existing gyrocopter parts, facilitating the extraction of geometric data needed for creating or updating engineering drawings.</li><li>&nbsp;Design Optimization:&nbsp;Detailed scans enable the analysis of current designs, identifying areas for improvement and optimization.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736299334695-6.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Conclusion</h2>Trackscan-Sharp provides valuable data support, enabling customers to correct CAD designs and improve overall product development. By doing so, it accelerates the research and development cycle while minimizing trial-and-error costs. Additionally, this versatile scanner can be utilized for quality inspection and control during production. NIKI Rotor Aviation’s commitment to innovation and precision has positioned them at the forefront of gyrocopter manufacturing. With the integration of Trackscan-Sharp, they not only address inspection and development challenges but also empower their clients to confidently take flight.

In the aviation industry, a gyrocopter manufacturer employs Scantech’s advanced optical 3D measurement system, TrackScan-Sharp. This cutting-edge technology enables precise and efficient scans of intricate components, enhancing product development and inspection.

3D Scanning Enhances Inspection and Product Development in Aviation Industry

As the global energy industry increasingly shifts towards sustainable and renewable sources, the demand for efficient and reliable power generation equipment, such as hydraulic turbines, continues to grow. In this context, the precision of critical components like the spiral casing is essential. Even minor dimensional deviations in the casing can lead to misalignments, reduced efficiency, and operational failures.Traditional measurement methods often fall short in accurately capturing the complex geometry and large scale of these components. <a href="https://www.3d-scantech.com/3d-scanners/" target="_blank">3D scanning</a> technology provides a precise, real-time, non-contact solution, enabling manufacturers to accurately capture the full dimensions of the spiral casing.&nbsp;<h3>Client Overview</h3>The client is a leading manufacturer of hydraulic turbines, specializing in the production of high-efficiency turbine systems for the global hydropower industry. They design and produce a wide range of turbine types and associated equipment, including spiral casings, critical for the turbine's performance.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547433436-1.jpg" style="width: 100%px;" class="fr-fic fr-dib">Given the complexity and large size of the spiral casings, the client needed a high-precision inspection solution to ensure dimensional accuracy, avoid assembly issues, and meet strict industry standards.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547446299-2.jpg" style="width: 100%px;" class="fr-fic fr-dib">To meet these needs, the client required a solution that could:<ul><li>Measure large, complex geometries accurately.</li><li>Detect, address, and prevent deformations or misalignments to ensure proper fit during assembly.</li><li>Provide real-time feedback for continuous quality control and adjustments.</li></ul><h3>Challenges of Traditional Measurement Methods</h3>Traditional measurement techniques, such as laser tracking and mechanical gauges, face significant limitations when it comes to accurately inspecting large, complex components like spiral casings. These challenges include:Limited Measurement Range: Conventional methods struggle to measure large-scale components accurately without frequent repositioning, leading to potential errors in data stitching and reduced efficiency.Susceptibility to Environmental Factors: Measurements taken in production environments can be influenced by temperature fluctuations, vibrations, or dust, affecting the accuracy and consistency of results.Inability to Capture Complex Geometries: Traditional tools can only measure discrete points, making it difficult to capture the full, intricate shape of the spiral casing, including curves, angles, and detailed surface features.Time-Consuming and Labor-Intensive: Manual measurements are slow and prone to human error, often requiring multiple iterations and inspections, which delays production and increases costs.These challenges highlight the need for a more advanced, efficient, and accurate solution, prompting the client to explore 3D scanning technology for its precision and ability to address these issues.<h3>Solution: 3D Scanning for Spiral Casing Inspection</h3>To overcome the limitations of traditional measurement methods, the client implemented <a href="https://www.3d-scantech.com/product_category/tracking-3d-scanner/" target="_blank">TrackScan Sharp&nbsp;3D scanning system</a>, designed for large-volume, high-precision measurements, provided an effective solution for inspecting the spiral casing with several key advantages:<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547468322-3.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h3 id="isPasted">Portable and Reliable On-Site Scanning</h3>The TrackScan Sharp was ideal for on-site measurement of the spiral casing, which is difficult to move due to its size. The handheld 3D scanning system’s portability allowed the client to conduct precise measurements directly in the workshop, improving operational efficiency.Its sturdy design ensured stable performance even in challenging workshop environments, remaining unaffected by vibrations, temperature changes, or noise. Its dynamic tracking further ensured the precise measurement on the vibrant shop floors.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547487791-4.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h3 id="isPasted">Highly-Efficient&nbsp;Measurement</h3>Equipped with on-board processor for edge computing, the 3D scanning system’s tracker output 3D coordinates in real time after processing images. It sped up the data transfer and the measurement process.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547503110-5.jpg" style="width: 100%px;" class="fr-fic fr-dib">Besides, its one-position measurement range is larger than that of traditional measurement method. With a few repositioning, it can efficiently capture the data of large-scale parts and ensure the precision by reducing the times of data alignment. Combined with its high scanning rate, the measurement was completed in just 2 hours.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547515051-6.jpg" style="width: 100%px;" class="fr-fic fr-dib">Precise Data Capture&nbsp;TrackScan Sharp enabled precise capture of the complete geometry of the spiral casing, including complex curves, intricate features, subtle deviations and hole diameters.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547528855-7.jpg" style="width: 100%px;" class="fr-fic fr-dib">The advanced algorithms ensured accurate measurement of dimensions and machining allowances. This 3D scanning system allowed the client to obtain precise data and ensured the parts manufactured are of high standards.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547542263-8.jpg" style="width: 100%px;" class="fr-fic fr-dib"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547554736-9.jpg" style="width: 100%px;" class="fr-fic fr-dib">Detailed Deviation AnalysisThe scanning data was processed to create a detailed <a href="https://www.3d-scantech.com/3d-model/" target="_blank">3D model</a> of the spiral casing, which was then compared to the original CAD model. This deviation analysis helped identify discrepancies and provided critical insights for quality control.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547571052-10.jpg" style="width: 100%px;" class="fr-fic fr-dib"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547580166-11.jpg" style="width: 100%px;" class="fr-fic fr-dib">The deviation color map allowed the client to identify dimensional deviations promptly, so that they minimized defects and ensured the casing met strict tolerances throughout the manufacturing process. It also highlighted specific machining allowances on the surfaces to be machined, ensuring precise machining. Additionally, the high-precision data, especially precise hole diameters, provided a valuable reference for subsequent assembly.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547594478-12.jpg" style="width: 100%px;" class="fr-fic fr-dib">The implementation of the TrackScan Sharp 3D scanning system successfully addressed the client's challenges, providing a comprehensive and precise solution that significantly improved the accuracy, efficiency, and reliability of the inspection process for the spiral casing.<h3>The Broader Impact and Future Outlook</h3>The integration of TrackScan Sharp 3D scanning system has not only addressed the immediate challenges in the precision inspection of spiral casings but also set a new standard for quality control in large-scale turbine manufacturing. By offering on-site measurement, improving measurement accuracy, reducing inspection time, and providing real-time feedback, the solution ensured the manufacturing of high-quality turbine components for the client’s global customers. Its intuitive feedback help manufacturers to monitor the production processes in real time, allowing them to make timely adjustments to reduce defect rates and achieve greater financial benefits.&nbsp;Looking forward, the <a href="https://www.3d-scantech.com/application/" target="_blank">application of 3D scanning</a> technology in turbine manufacturing is expected to continue evolving, with future advancements in scanning precision, speed, and automation. The ability to detect and correct deviations in real time will play a critical role in further streamlining production processes and minimizing defects. As the demand for high-performance, reliable turbine systems grows, especially in the renewable energy sector, the adoption of advanced technologies like TrackScan Sharp will become increasingly vital to maintaining competitiveness and meeting industry standards.The widespread adoption of 3D scanning technology will not only enhance product quality but also contribute to greater sustainability, by optimizing production processes, reducing waste, and ensuring longer product lifecycles. As Scantech continues to innovate, our <a href="https://www.3d-scantech.com/3d-solution/" target="_blank">3D&nbsp;solutions</a> are poised to play a pivotal role in shaping the future of manufacturing, helping industries meet the challenges of the modern world with precision, speed, and efficiency.

Scantech's TrackScan Sharp 3D scanning system provides a cutting-edge solution for inspecting spiral casings in turbine manufacturing. By offering high-precision measurements, real-time feedback, and rapid data capture, it enhances production efficiency and ensures the highest quality standards.

How 3D Scanning Technology Revolutionizes Spiral Casing Inspection in Turbine Manufacturing

<html><head></head><body>Addressing the challenges of compressor maintenance&nbsp;<iframe id="67c216d2e309bcb9aa8eda02" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/arduino-opta-wifi?iframe=true" frameborder="0" scrolling="no"></iframe>Air compressors are crucial for a vast range of industrial processes, as essential components for anything from pneumatic tools to production lines. As a result, undiscovered issues or poor maintenance plans may lead to expensive downtime, significant energy loss, and equipment failure.Based in Louisville, Kentucky, as an industrial equipment maintenance company and leading service provider in the air compressor industry, <a href="https://www.atlasmachine.com/" target="_blank" rel="noopener noreferrer">Atlas Machine and Supply</a> set out to find a solution that could predict compressor faults in real time, provide actionable insights, and scale across different industrial environments.&nbsp;Discovering Arduino technologyThe intuition came unexpectedly. Richie Gimmel, CEO of Atlas, discovered Arduino thanks to his son, who shared with him a video by influencer Mark Rober about an ingenious project made with the open-source platform. Although the specific video was for a glitter bomb against “porch pirates” and completely unrelated to the industrial context, it allowed Gimmel to see the potential of Arduino technology to revolutionize the monitoring of industrial compressors with a flexible, affordable solution that was compatible with different equipment.&nbsp;<iframe width="640" height="360" src="https://www.youtube.com/embed/XfOalsSUQsY?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> A scalable, data-driven solutionAtlas turned to a combination of <a href="https://www.arduino.cc/pro/hardware-arduino-opta/" target="_blank" rel="noopener noreferrer">Arduino Opta</a> and <a href="https://cloud.arduino.cc/" target="_blank">Arduino Cloud</a>, integrated with AWS, to design an edge-to-end solution capable of real-time monitoring and predictive fault detection. The system relies on a network of sensors that measure critical parameters like vibration, temperature, and pressure even across diverse fleets, anywhere in the world. This data is processed locally using edge computing and transmitted to the cloud for further analysis.The custom solution allows the company’s personnel as well as clients to visualize equipment performance in real time, and sends out alerts whenever anomalies are detected – so action can be taken before minor issues escalate.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM0MDEwOTUwNzQzLWRhc2hib2FyZC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">Benefits for efficiency and sustainabilityAll in all, by harnessing real-time data and edge computing, the company has set a new standard for efficiency and reliability in the industrial compressor market. The benefits for Atlas and its clients include:&nbsp;• Reduced downtime: Predictive analytics allow maintenance to be scheduled proactively, minimizing unexpected breakdowns.• Extended equipment life: Early fault detection prevents wear and tear, prolonging the lifespan of critical components.• Improved customer satisfaction: The solution enables more reliable operations, enhancing trust and loyalty.&nbsp;Curious to find out more? Read the <a href="https://www.arduino.cc/pro/success-story-atlas-machine-and-supply/" target="_blank">full case study on the Arduino website</a>.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM0MDExMjk0NTkzLU9wdGEgMV9sby5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></body></html>

The flexible Arduino Opta combines with Arduino Cloud for remote monitoring and predictive maintenance of industrial air compressors.

This leader in industrial equipment repair and manufacturing used Arduino’s industrial technology to develop a scalable solution – with positive impact on operational efficiency for its clients.

Atlas Machine and Supply Creates a Data-Driven Predictive Solution for Compressor Maintenance

Cleaning the seas of unexploded bombs, mines and other ordnance is essential but dangerous work. The farther that bomb disposal officers can stay away from explosive devices, the lower the risk they face. This is why the US Navy and other military forces prefer to put underwater remotely operated vehicles (ROVs) in harm’s way. And the chosen vehicle for many is supplied by US-based VideoRay, manufacturer of the Ally, Defender and Pro 5 ROVs. <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733910037880-Videoray+customer+case_Figure+1.png" style="width: 100%px;" class="fr-fic fr-dib"> VideoRay’s products have gained support from the demanding military community because of their combination of small size and portability, high power and lifting ability, flexible payload options, and reliability. And playing an important part in the stability system of the VideoRay ROVs, making remote operation of the vehicle, its video camera and other accessories easier, is the high performance of the <a href="https://www.movella.com/products/sensor-modules" target="_blank" rel="noopener noreferrer">Xsens MTi</a> Attitude and Heading Reference System (AHRS) sensor on board.&nbsp;A robotic diver with high-resolution camera visionThe Ally, Defender and Pro 5 ROVs operate like a diver, but without putting a human life at risk. &nbsp;Built to a modular design and tethered to a control panel on the surface, the ROV has a 4K camera, optional auxiliary cameras &nbsp;and powerful lights to enable the remote operator to view the scene in detail, and forward-looking sonar to assist with piloting the vehicle in murky water and other low visibility environments. &nbsp;VideoRay offers a wide range of accessory options for equipping the vehicle with gripping, lifting and other tools. And with seven 1hp thrusters on board, the ROV can move fast through the water and lift heavy objects with ease from the sea floor.&nbsp; <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733910100730-Videoray+customer+case_Figure+2.png" style="width: 100%px;" class="fr-fic fr-dib"> Since the ROV is tethered, it can be remotely piloted. The VideoRay products are widely used by the US Navy on explosive ordnance disposal missions. Here, the ROV navigates semi-autonomously to a zone of interest, heading for destination co-ordinates programmed in by the operator. Once the ROV reaches the zone of interest, a remote pilot takes over to locate the explosive device, and perform the mission’s operation on it. Inertial navigation technology keeps the ROV on track – a combination of a DVL (Doppler velocity log), GPS satellite positioning, Greensea internal navigation software, a pressure sensor for depth measurement, and the Xsens MTi AHRS sensor for tracking the vehicle’s heading. The attitude readings from the sensor also support the operation of the propulsion system, enabling the vehicle to maintain a stable posture underwater.&nbsp;Accurate heading keeps the ROV on trackAndy Goldstein, Chief Technology Officer of VideoRay, explains that the heading measurements are normally the biggest source of error in marine inertial navigation systems. This means that the accuracy of the AHRS has a substantial impact on the ability of the ROV to reliably reach the destination programmed into it. He says, ‘VideoRay’s evaluation of the Xsens MTi AHRS sensor convinced us that its performance would meet the high standards that we set for the inertial system on the ROV. Movella supplies the sensors with a robust software development kit to streamline the system development process. The SDK is also supported by magnetic calibration software supplied by Movella. This means that users can calibrate the sensor’s heading measurements to adjust for variations in the earth’s magnetic field. This fine tuning of the heading system’s outputs is absolutely crucial to the vehicle’s ability to stay on track over missions stretching for hundreds of meters from the starting position.’The other key factors in VideoRay’s decision to use Xsens MTi AHRS sensors are its size and availability in production volumes. Its small size made it easier for the VideoRay engineering team to fit the sensor inside the compact ROVs, which can be carried by a single person. &nbsp;&nbsp; <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733910118532-Videoray+customer+case_Figure+3.png" style="width: 100%px;" class="fr-fic fr-dib"> The powerful propulsion and reliable autonomous navigation capabilities of the <a href="https://videoray.com/" target="_blank" rel="noopener noreferrer">VideoRay</a> ROVs have been tested extensively in thousands of explosive ordnance disposal missions operated by the US Navy and others. The ROVs are also in use in many applications which require their power, portability and flexibility: offshore energy mapping and production, ship maintenance, inspection of underwater assets such as dams, search and rescue and others.&nbsp;And in all of them, the inertial navigation and handling of the vehicle are assisted in large part by the high-performance Xsens MTi AHRS sensor on board.&nbsp;

With Xsens MTi AHRS

VideoRay underwater ROVs on board provide reliable autonomous navigation for hazardous US Navy missions

<h3 id="isPasted">Why Choose Metal 3D Printing for Fixture Construction?</h3>Metal 3D printing transforms fixture construction by enabling customized, efficient, and precise solutions tailored to specific applications. Its ability to directly produce components from CAD designs overcomes the limitations of traditional manufacturing methods.Key Benefits Include:<ul><li>Design Flexibility: Additive manufacturing allows for the creation of intricate geometries and application-specific features that traditional methods often cannot achieve. Fixtures can be optimized for exact functionality, enhancing performance and reliability.</li><li>Time Efficiency: The streamlined process of designing and producing fixtures with 3D printing significantly reduces lead times. From concept to production, projects can be completed in days rather than weeks, allowing manufacturers to respond quickly to changing needs.</li><li>Material Savings: Unlike traditional subtractive manufacturing, 3D printing uses only the material required for the design, reducing waste and lowering material costs. This makes it a more sustainable and economical choice.</li><li>Cost-Effectiveness for Customization: 3D printing eliminates the need for tooling, making it ideal for low-volume or highly customized fixtures. Manufacturers can produce tailored solutions without incurring additional setup costs.</li><li>Improved Workflow: The ability to go directly from CAD data to production simplifies the manufacturing process, eliminating the need for extensive preparation or machining. This leads to faster execution and greater adaptability.</li><li>Durability and Strength: Metal 3D printing materials like stainless steel provide the robustness needed for demanding industrial environments, ensuring that fixtures can withstand rigorous use.</li></ul>

Metal 3D printing at Hoedtke metal solutions

Hoedtke metal solutions is using metal 3D printing to print fixture constructions. The video demonstrates how the use of additive manufacturing helps them to improve their processes and capacities. 

Fixture Construction

Researchers at the Italian Institute of Technology (IIT) are transforming human-robot collaboration with adaptive interfaces, enabling real-time robot adjustments and safe, seamless interactions.Key takeaways:<ul><li>Real-time adaptation for collaboration:&nbsp;Sirintuna and Ozdamar developed an adaptive collaborative interface (ACI) that allows robots to adjust their actions to the human movement intention in real-time, improving teamwork and efficiency.</li><li>Safety and predictability:&nbsp;Safety protocols and torque-controlled robots reduce risks in human-robot interaction, though unpredictable human behavior remains a challenge.</li><li>Xsens motion capture: The researchers use Xsens for precise, continuous movement data, crucial for interpreting human intentions and enabling seamless robot-human collaboration.</li><li>Future applications:&nbsp;The research has potential in healthcare, emergency response, and home assistance, aiming for robots that adapt intuitively in real-life, unstructured environments.&nbsp;</li></ul>Humans have been working with machines for centuries, and with the ongoing robotics revolution, this collaboration is becoming more equal. Researchers Doganay Sirintuna and Idil Ozdamar from the Italian Institute of Technology (IIT) are at the forefront of this change, investigating how robots can effectively work with humans in tasks such as carrying and delivering objects.&nbsp;The new challenge&nbsp;IIT has been actively researching human-robot collaboration for several years, showcasing robots that can perform a variety of tasks, from assisting in drilling holes to serving cups of coffee. &nbsp;Researchers Doganay Sirintuna and Idil Ozdamar, from the Human-Robot Interfaces and Interaction Laboratory, are developing a framework that allows robots to assist with transporting objects. Their framework, called Adaptive Collaborative Interface (ACI) uses haptic feedback and motion capture data to enable robots to adjust their speed and position for better teamwork with humans.&nbsp;In Ozdamar's study, “<a href="https://arxiv.org/abs/2209.14009" target="_blank" rel="noopener noreferrer">Carrying the Uncarriable: A Deformation-Agnostic and Human-Cooperative Framework for Unwieldy Objects Using Multiple Robots</a>,” a framework is presented for one person and two robots to carry a large, deformable object using flexible straps. In a related study by Sirintuna and Ozdamar, “<a href="https://arxiv.org/abs/2201.10392" target="_blank" rel="noopener noreferrer">Human-Robot Collaborative Carrying of Objects with Unknown Deformation Characteristics</a>,” they explore handling items from flexible ropes to rigid rods. By analyzing human movements and force feedback, robots can detect the deformability of the handled objects and adapt their actions. &nbsp;<iframe width="640" height="360" src="https://www.youtube.com/embed/Q3sA6YzTaaE?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>Sirintuna and Ozdamar's research focuses on robots consisting of a base with wheels (mobile manipulators) and a robotic arm with multiple joints (known as collaborative robots or cobots). They explain, "In our setup, we have 9° of freedom, and with wheeled robots, you can perform fast movements. So, we selected an industrial robot to concentrate on collaboration tasks."&nbsp;The choice of Xsens &nbsp;In their work, Sirintuna and Ozdamar rely heavily on <a href="https://www.movella.com/products/motion-capture" target="_blank" rel="noopener noreferrer">Xsens motion capture</a> to collect accurate movement data to guide the robots. Xsens allows the researchers to conduct the experiments with minimal setup—making it a practical choice for laboratory environment. Sirintuna and Ozdamar stress the importance of precise, continuous data when working in close collaboration with humans. They appreciate Xsens’ reliability, noting, “We used Xsens because its data was very continuous, which allowed us to provide a reliable stream of data for the human-robot collaboration. Optical sensors we have tried can experience jumps in position, affecting the performance of our framework.”&nbsp;A key focus of their research is interpreting human intentions through movement data. Xsens provides detailed kinematic data, enabling them to categorize actions such as standing still, pushing, or pulling. Through repeated training, they achieved a 98% accuracy in predicting human movements within just three months. “We label specific joint positions and angles as pushing or pulling and use these as input for our system,” Ozdamar explains. Sirintuna and Ozdamar also developed an algorithm that interprets human’s rotational intent by analyzing torso and hand movements, with the goal of creating robots that assist efficiently in tasks like turning while carrying objects. &nbsp;The research results &nbsp; As a result of applying the adaptive collaborative interface, Sirintuna and Ozdamar found that cobots can handle tasks with higher precision, anticipating human movements in real time and adjusting actions based on nuanced data. With the help of a robot operating under ACI in the research on the different deformable objects, "participants completed the task faster, with less effort and higher effectiveness". In the research with two robots assisting one person with transporting a bulky object using deformable straps, the ACI allowed robots to have faster response and better alignment of the movement and required a lesser force input from the person, making the lifting task easier.&nbsp;The findings underscore the power of applying ACI for human-robot collaboration scenarios and lay a foundation for future research in this area.&nbsp;<iframe width="640" height="360" src="https://www.youtube.com/embed/ounQmCdYlC4?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> The future of human-robot collaboration and humanoids&nbsp;Looking ahead, Sirintuna and Ozdamar see their research supporting applications in healthcare, emergency response, and home assistance, as well as enabling robots to become common in public spaces and workplaces to meet needs, for example, in agriculture, affected by climate change. The researchers note that “human-robot teams that leverage human adaptability and decision-making can perform tasks with the flexibility required in unstructured environments.”&nbsp;However, making this robotized future reality requires addressing safety concerns in human-robot collaboration. The research robots are torque-controlled, equipped with soft joints, and programmed to avoid reacting to unexpected high-velocity impacts or large force inputs. Yet, as the researchers point out, for real-world applications, the unpredictability of human behavior remains the greatest challenge. “We design algorithms based on expected movements, but humans often behave in unexpected ways,” says Sirintuna. Ozdamar adds, “We can ensure slightly more safety on the robots’ side than on a person’s because we can predict the robot’s behavior.”&nbsp;Ultimately, Sirintuna and Ozdamar’s work lays a foundation for future robots capable of safe, intuitive collaboration with humans, bringing us closer to a world where robots seamlessly assist in our daily lives.&nbsp;

By Xsens MVN Analyze

IIT Develops Adaptive Collaborative Interface for Safe Human-Robot Interaction with Xsens motion capture

The Challenge: Simplifying Data Integration in Complex Manufacturing Environments<a href="https://www.techgest.it/?origin=arduino" target="_blank">Techgest</a> is a leader in ERP integration and software development, delivering custom solutions to a wide range of clients – from mechanical manufacturing to fashion. One consistent challenge they noticed across all industries is managing the massive volumes of data generated by industrial operations. Therefore, the company set out to develop an affordable, highly adaptable IO device that could facilitate seamless data integration with their <a href="https://www.techtree.it/?origin=arduino" target="_blank">TechTree MES platform</a>, while also enabling real-time monitoring and efficiency improvements.&nbsp;The result is TechIO, a device that can be implemented quickly and works across a range of equipment, independent of third-party platforms, to enable seamless integration of production data with their proprietary MES and WMS platform.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731940123834-tecnico-quadro.jpg" style="width: 100%px;" class="fr-fic fr-dib">&nbsp;A Flexible, Open-Source Solution for Data AcquisitionTo meet these goals, Techgest turned to the <a href="https://www.arduino.cc/pro/portenta-machine-control" target="_blank">Arduino Portenta Machine Control</a>. This powerful, open-source control unit provided the flexibility needed to develop a custom IO device with full API support, allowing clients to integrate even legacy production machines into TechTree. Its customizability and cost-effectiveness enabled Techgest to implement TechIO swiftly, keeping costs under control while avoiding the limitations of vendor-specific solutions.According to Stefano Girardi, CEO of Techgest, “We evaluated various standard IO interfaces but found them lacking in terms of power and customization. We needed a solution that would allow us to build our own system exactly as imagined, without vendor lock-in.”&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731940167352-PMC.jpg" style="width: 100%px;" class="fr-fic fr-dib">Benefits of TechIO for ManufacturersTechIO enables manufacturers to leverage the real-time capabilities of the TechTree platform. Clients can now monitor production processes in real time, improve energy management, and enhance quality control KPIs, all without expensive retrofitting. One customer shared that the cost savings from energy efficiency alone helped them justify an investment of approximately €1 million in just 18 months, making TechIO a smart solution for boosting both operational and financial efficiency.&nbsp;Curious to find out more?&nbsp;Read the&nbsp;<a href="https://www.arduino.cc/pro/case-studies-techgest" target="_blank">full case study on the Arduino website</a>.

The Arduino Portenta Machine Control brings Industry 4.0 within reach for any manufacturer.

By utilizing the Arduino Portenta Machine Control, Techgest helped manufacturing clients improve real-time monitoring, energy efficiency, and production optimization – all without vendor lock-in or costly retrofits. 

Techgest Unlocks Industry 4.0 for Manufacturers with Smart ERP Integration

The Challenge: Optimizing Real-Time Quality Testing<a href="https://www.snaptron.com/" target="_blank">Snaptron</a>, a leading manufacturer of tactile dome switches used across industries from aerospace to medical, originally developed the Sapphire Force Testing Machine to ensure rigorous quality control. However, as technology advanced, their Director of Engineering, Kevin Albertsen, recognized the need for an upgrade. Their existing setup, which used stacked PC/104 cards on a single-board computer, was complex and costly, lacking the efficiency needed for real-time data analysis.Snaptron’s goal was clear: streamline the system to reduce expenses and increase processing speed, providing a high-quality solution without a hefty price tag. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxOTM5NDQzNjk4LVNhcHBoaXJlX2xvLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width:100%px" class="fr-fic fr-dib" />A Simple, Cost-Effective Solution: The Portenta H7 Lite  <iframe id="635a907b01e7d30008f114c0" width="250" height="440" src="https://wevolver.com/iframe/specs/arduino-portenta-h7?iframe=true" frameborder="0" scrolling="no"></iframe> Snaptron chose the <a href="https://www.arduino.cc/pro/hardware-product-portenta-h7/" target="_blank">Portenta H7 Lite</a> to upgrade the Sapphire machine. The board’s versatility allowed for rapid prototyping and iteration, reducing development time significantly. With seamless data transfer via USB and straightforward integration of digital and analog connections, Snaptron could simplify in-house PCB assembly and low-volume production.Albertsen noted the benefit of Arduino’s extensive library support and open-source resources, which accelerated the prototyping phase, freeing up resources for other projects. The Portenta H7 Lite’s cost-effectiveness also helped Snaptron manage their budget, allowing for further improvements to their system. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxOTM5NDYzNjI0LUFCWDAwMDQ1XzA1LnVuYm94LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width:100%px" class="fr-fic fr-dib" />Expanding Market Opportunities with a New Product LineWhat began as an internal solution for quality control quickly revealed market potential. Snaptron discovered that customers also needed a similar force-displacement switch tester, prompting them to develop a commercial product based on the upgraded Sapphire. This new offering has since opened up a fresh revenue stream, showcasing how rapid prototyping can lead to unexpected opportunities. Curious to find out more? Read the <a href="https://www.arduino.cc/pro/case-studies-snaptron" target="_blank">full case study on the Arduino website</a>.

The Arduino Portenta H7 Lite provides an efficient and cost-effective solution for quality testing.

Snaptron optimized their quality testing machine, Sapphire, to enable faster data processing and lower costs. Leveraging Arduino’s Portenta H7 Lite, they not only improved in-house quality control but also opened up a new market segment for force-displacement testing solutions. 

Case studys

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