Automated 3D scan based CAD-repositioning for design and verification in one-off construction

The presented engineering discipline one-off construction is characterized by a multiplicity of manual processes. As almost all modern product developments, the manufacture is based on the creation and consistent use of digital models. Quality of underlying data can vary greatly and it is not certain that digital models match the actual state of construction. This can result in the need for rework after production or installation. Especially challenging in the area of premium products, for which high quality, scarce materials are used and tight schedules are defined. If physical products are reworked, the corresponding digital models must be manually maintained. At present, attempts are being made to counteract these late adjustments by means of physical mock-ups or visual inspection of 3D scan data. Such scan data is used for automated adaptation of underlying digital models to the actual state of the physical construction. Existing Point Cloud Library functionalities were adapted and further algorithms were designed. The developed software backend was integrated into the existing software architecture. During the software development, great care was taken to ensure that the backend is based on open source content. The results show significant improvements of the data basis for the subsequent engineering activities. This will lead to a significant reduction of manual effort and rework, ensuring development cycles and even shorten delivery times. It reduces costs in the product creation process and sustainably strengthens confidence in digital models used. It has been shown that automation of design processes can have productivity-enhancing effects in one-off construction.