Project Details

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Automated 3D Scanning and Digital Reconstruction of Small-Diameter Carbide End Mills

Company: Seco Tools

Major(s):
Primary: CMPEN
Secondary: ME
Optional: CMPSC

Non-Disclosure Agreement: NO

Intellectual Property: NO

Project Description: Precision cutting tools such as carbide end mills contain complex geometric features that are difficult to capture with conventional low-cost 3D scanning systems. This project will develop and validate an enhanced OpenScan3-based scanning platform (https://openscan.eu/blogs/news/openscan3-beta-whats-new ) capable of accurately digitizing a 10 mm solid carbide end mill for reverse engineering, geometry analysis, and digital manufacturing applications. OpenScan3 provides a flexible open-source foundation with automated motion control, high-resolution imaging support, and photogrammetry integration. The student team will investigate methods for improving the scanning of highly reflective carbide surfaces through optimized fixturing, lighting, imaging, and photogrammetry techniques. The resulting system will be evaluated for its ability to generate accurate 3D models suitable for engineering analysis and comparison with known tool geometries. Project Deliverables: -Design and build a modified OpenScan3 scanning system optimized for small cutting tools. -Develop a precision fixture and positioning system for scanning 10 mm carbide end mills. -Evaluate and implement appropriate imaging, lighting, and surface treatment strategies to improve scan quality. -Generate accurate 3D digital models of scanned cutting tools. -Validate scan accuracy through comparison with measured tool dimensions. -Create complete documentation including system design, bill of materials, operating procedures, and recommended improvements. -Deliver a final technical report and presentation summarizing the system performance, accuracy, limitations, and future development opportunities.