3D scanning plays a pivotal role in modern 3D printing workflows, acting as both a starting point and a quality control measure. Professionals across engineering, product design, and research utilize 3D scanners to efficiently create digital models for 3D printing. This process streamlines the incorporation of existing designs through reverse engineering, digitizes intricate hand-sculpted creations, and accurately captures the human form for customized applications.
Beyond initial design, 3D scanning is invaluable post-fabrication. It facilitates rigorous quality checks, verifying the precision of 3D printed parts. Furthermore, analyzing scanned parts after use can reveal performance insights, highlighting areas for design improvement in subsequent iterations.
The market offers a diverse array of 3D scanners, ranging from handheld to desktop models, making the selection process complex. Choosing the optimal 3D scanning system for specific applications and budgets requires careful consideration. This guide delves into the critical factors to evaluate when investing in a 3D scanner, and showcases the transformative applications unlocked by the synergy of 3D scanning and 3D printing.
Exploring Different Types of 3D Scanning Technologies for 3D Printing
Several 3D scanning technologies are available today, each with unique strengths and limitations. Understanding these differences is crucial for selecting the best option for your 3D printing needs.
Laser Triangulation 3D Scanners
Laser triangulation scanners employ projected laser light to capture millions of data points per second. The light reflected from the object’s surface is detected by the scanner’s sensor, enabling precise geometric data acquisition. Renowned for their high accuracy, these scanners excel with detailed, opaque objects.
However, laser triangulation scanners have drawbacks. Their reliance on a stable laser source limits their portability, and they are often challenged by transparent or reflective surfaces. While reflective markers can mitigate this, their application and removal can be cumbersome. Safety is also a concern, as laser light can be harmful to eyes, necessitating precautions when scanning living subjects. Always consult manufacturer guidelines to ensure eye safety.
Structured Light 3D Scanners
Structured light scanners, also known as white light or blue light scanners, typically utilize a projector and two angled cameras. They project light patterns onto the object, and the cameras capture the pattern deformations caused by the object’s shape. These distortions are then processed to create a 3D digital snapshot.
Available in both stationary and portable configurations, structured light scanning is the predominant technology in handheld 3D scanners. Its safety for biological subjects makes it popular in medical fields, particularly when scanning moving subjects. While traditional white light scanners were once slower than laser triangulation, advancements have narrowed this gap.
Depth-Sensing Camera 3D Scanners
Depth-sensing cameras project an infrared (IR) dot pattern to map 3D scenes. These cameras are user-friendly and represent the most affordable 3D scanning option. However, their simplicity comes at the cost of lower accuracy and resolution, potentially losing fine details. While suitable for larger objects, accuracy diminishes with distance and steep angles.
Photogrammetry for 3D Scanning
Photogrammetry is the technique of deriving measurements from photographs. By capturing overlapping photos of an object from various angles, software algorithms convert these images into a 3D model. This method is widely used in smartphone 3D scanning apps due to modern phone camera capabilities. Photogrammetry is the most budget-friendly but least accurate method for 3D printing applications and is generally not recommended for professional use requiring high precision.
LiDAR 3D Scanners
LiDAR (Light Detection and Ranging) sensors are integrated into some high-end smartphones and tablets, like recent iPhone Pro and iPad Pro models. LiDAR elevates smartphone scanning capabilities beyond photogrammetry, offering improved performance for occasional scanning tasks. However, smartphone-based 3D scanning should be considered entry-level. Users often require additional CAD software work to refine meshes, fill gaps, and optimize models for professional 3D printing. Smartphones use fewer light points, resulting in less detail compared to dedicated 3D scanners. iPhones can serve as adequate substitutes for basic model capture and digital transfer, especially for users proficient in CAD design.
Key Factors to Consider When Choosing a 3D Scanner for 3D Printing
3D Scanner Accuracy vs. Price
Accuracy is a primary differentiator among 3D scanning technologies, and generally, higher accuracy correlates with higher cost. The required tolerances of your 3D printed parts should guide your accuracy needs for a 3D scanner.
| High Price, Highest Accuracy (>$15,000) | More Affordable, High Accuracy (<$12,000) | Low Price, Low Accuracy |
|---|---|---|
| Zeiss T-Scan Hawk, Scantech Simscan, EviXscan Optima+ M, Creaform HandyScan 307 Silver Series | Peel 3D Peel 1, Peel 2 & Peel 2-SFARO, Freestyle 2, Polyga Compact S1 | iPhone Pro and iPad Pro, Structure Sensor, Matter and Form 3D Scanner V2, Revopoint POP |
Laser and structured light scanners offering accuracy of 0.1 mm or better are well-suited for professional applications and complement high-resolution 3D printers. Formlabs stereolithography (SLA) resin 3D printers, such as the Form 3+, achieve similar accuracy and build volumes comparable to many desktop 3D scanners.
Beyond accuracy, resolution—the density of captured points—is also critical. Higher resolution scanners capture finer details. A high-accuracy, low-resolution scanner might capture the overall shape of jewelry on a statue but miss intricate details on a ring. Project requirements dictate whether resolution is a crucial factor.
Accuracy represents the measurement error, while resolution denotes measurement density. Accuracy definitions can vary by manufacturer and technology. Handheld scanner accuracy can depend on distance and scan reconstruction quality, while desktop scanners offer consistent accuracy within their scan volume. Compare specifications carefully when accuracy is paramount.
Structured light scanning generally provides superior resolution and accuracy compared to laser scanning. For artistic applications where detail is paramount but absolute accuracy less so, especially if parts don’t require precise assembly, photogrammetry can be a cost-effective option.
Depth-sensing cameras and photogrammetry are suitable for scanning large objects for 3D printed scale models or capturing human body shapes. Entry-level laser scanners offer a starting point for replicating small objects at a 1:1 scale. While less accurate than high-end models, they can capture sufficient detail for decorative objects where extreme precision is not essential. For infrequent 3D scanning needs, digitization services offer scanning, CAD translation, and accuracy inspection.
3D Scanner Volume and Coverage
Scan volume, the capture area of a 3D scanner, varies significantly. Select a scanner that matches your object sizes to optimize cost, as larger scan volumes typically increase price.
Handheld scanners offer greater flexibility for scanning objects of varying sizes, from basketballs to rooms. High-end handheld scanners extend this range further, accommodating objects requiring precise measurement that exceed desktop scanner capacity. Their rapid capture speed also makes them ideal for human measurements in ergonomics and medical applications, where subject stillness is challenging.
Occlusion—areas hidden from the scanner—causes gaps in the 3D model. Software can automatically repair minor gaps for 3D printing, but these repairs are often inaccurate. For high-precision parts, manual gap filling is necessary. MeshMixer tutorials offer advanced techniques for 3D file editing and repair for 3D printing.
Turntables enhance scanner coverage by rotating objects. Sophisticated turntables with multi-axis movement improve capture from multiple angles, crucial for reverse engineering complex parts with deep features that are difficult to access from a single viewpoint.
Cost considerations are straightforward: budget and frequency of scanner use dictate spending. Higher-cost scanners capture finer details and require less CAD touch-up. Handheld scanners are often pricier due to portability. The low-cost market offers diverse options, requiring careful evaluation based on specific needs.
Flowchart: Selecting the Ideal 3D Scanner for Your 3D Printing Projects
Use this flowchart to navigate scanner selection based on accuracy, scan volume, and budget considerations.
Download the high-resolution version of this infographic here.
How 3D Scanning Complements 3D Printing
A 3D scanner expands the capabilities of a 3D printer, enabling the replication of virtually any object’s shape. Together, they form a robust digital workflow, streamlining and enhancing processes across diverse industries.
3D scanners output triangular meshes representing object surfaces at real-world scale. These scans can sometimes be directly 3D printed without CAD modifications. Hybrid workflows combining solid CAD models with scanned data are also powerful. For example, customized ergonomic designs can integrate scanned human body imprints with mechanical components.
3D scanners are also essential for verifying 3D printed part accuracy. Metrology-grade scanners provide precise insights into material performance and dimensional accuracy in demanding applications.
Combining 3D printing and 3D scanning enables powerful workflows:
- Reverse engineering for replacement parts and custom ergonomic products.
- Replication and restoration in art and jewelry.
- Custom earpieces in consumer audio.
- Patient-specific solutions in dental and medical fields.
- Metrology for manufactured object validation.
Building a Digital Workflow with 3D Scanning and 3D Printing
3D scanners and 3D printers are fundamental components of digital workflows across industries. Download our white paper or watch our webinar for a detailed exploration of integrating 3D scanning to enhance part design and production, and to discover how 3D printing and 3D scanning empower diverse workflows in engineering, product design, and beyond.
Explore Formlabs 3D printers and request a free sample 3D printed part to experience the possibilities firsthand.
