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Lucy

Physical Digital make TCT Awards 2019 finalist list

TCTAwards 2019 Finalist Logo

We are extremely proud to announce that we have been shortlisted for the TCT Awards 2019.

Our entry ‘Nadcap Accredited 3DSL Measurement’ has been reviewed by the TCT Expert Advisory board and has been voted as a finalist for the TCT Inspex Application Award.

The TCT Awards celebrate the innovators, technologies and collaborators behind the best examples of 3D technology across the globe and are open to companies offering design-to-manufacturing innovation.

 

What is the TCT Inspex Award? :

In the words of the TCT Award Team “If you can’t measure it, you can’t make it”, and as specialists in the field of metrology we couldn’t agree more! Accurate and fully traceable measurement is vital, especially when it comes to liability. The quality and accuracy of the data delivered by Physical Digital are provided with an unbroken chain of traceability back to international standards. The Inspex Application Award seeks to commend the most significant case study in the field of metrology and inspection.

Our entry ‘Nadcap Accredited 3DSL Measurement’

Physical Digital® are the first business in the world offering 3D Structured Light Scanning (3DSL) services accredited to Nadcap standards. Nadcap is an unprecedented cooperative industry approach to improve quality, while reducing costs, for quality assurance throughout the aerospace and defence industries.
With Physical Digital’s Nadcap 3D Scanning service our customers can be confident in the accuracy and precision of the data delivered for their project as it comes with full traceability.
The team at Physical Digital offer a suite of 3D Structured Light (3DSL) optical measurement services using the industry leading GOM metrology systems. Our highly trained and experienced team of engineers provide both in-house and mobile scanning services. Following measurement we are proud to offer in-house design services for full product reverse engineering. For more information on our reverse engineering services please see our website.

 

Looking forward to the final!

We are very much looking forward to the awards ceremony which is due to take place on Wednesday 25th September 2019 and is being held at the National Conference Centre (NCC) in the West Midlands, so “watch this space”.

Three other entries are joining us as finalists within the TCT Inspex Application category and we would like to send our congratulations.

 

Contact us

For all your 3D scanning, measurement and inspection requirements or to discuss reverse engineering, contact our experienced team on 01483 750200 or via our contact us page or email info@physicaldigital.com and we will be pleased to help you with your enquiry.

Our 3D Scanning systems

3D scan of strawberry

What 3D scanning equipment do you use?

One of the questions we get asked by our customers is “What 3D scanning equipment do you use and why?”

There are many types of 3D scanning equipment available on the market today, you can even download apps to 3D scan an object on your phone, however the fundamental difference is the level of accuracy and repeatability that you achieve.
Our MD Tim Rapley introduced the UK’s first GOM 3D scanning systems during his time at McLaren. Since then, the technological advancements made by the GOM company have earned them a prestigious reputation as leaders in the world of metrology.

3D scanning is the process of capturing a physical object and collecting surface data to generate a point cloud or polygon mesh that can be used for product design and development, analysis or help to refine production processes and improve product efficiency.

To demonstrate this, we decided to use an everyday item to showcase our metrology system’s capability and with Wimbledon in full swing (excuse the pun…net!) and an expected 166,055 portions of strawberries and cream being consumed this year, we thought a strawberry would be a good choice!

A strawberry has a lot of surface detail and as we specialise in capturing surface geometries, it brilliantly showcases the capability of the industry-renowned GOM metrology systems used by our expert team and the images demonstrate the level of accuracy that can be achieved. At Physical Digital we pride ourselves on the expert knowledge of our engineers and our rigorous processes and procedures such as environmental control, to ensure that we capture your project at very high-levels of accuracy.

Our GOM 3D scanning systems

Here at Physical Digital® we offer a suite of 3D Structured Light (3DSL) optical measurement services using the industry leading GOM 3D ATOS scanning systems.

GOM ATOS Triple Scan (8M)

This flexible scanning system is most commonly used for our mobile measurement services, allowing us to provide you a flexible service at your premises therefore minimising downtime. GOM ATOS Triple scanners are high resolution, optical digitizers that deliver rapid and precise three-dimensional measuring data. This can be used for the measurement and inspection of many industrial parts and when combined with our GOM TRITOP Photogrammetry systems can be used to capture larger objects such as wind turbines, boat hulls and train carriages etc.

The ATOS Triple Scan technology works by projecting a fringe pattern (Structured Light) onto the surface of the object which is recorded by two cameras and is based on the stereo camera principle. The narrow-band blue light enables precise measurements to be carried out independently of environmental lighting conditions, improving overall accuracy.
Using triangulation principles, the sensor accurately measures the divergence and convergence of the pattern, creating a high-density point cloud of surface measurements.

GOM ATOS Compact Scan (12M)

This is another of our mobile 3D scanning systems that is used for a wide range of applications. Its interchangeable lenses provide small to large fields of view with high detail accuracy. This enable a sharp and precise scan result, which lends itself perfectly for inspection and reverse engineering.

Both mobile 3D scanners also enables probing, which enables our engineers to capture deep pockets, bores holes or areas that cannot be accessed optically (line of sight).

GOM ATOS ScanBox 5120 (16M)

Based at our facility in Guildford, Surrey our GOM ATOS ScanBox is ideally suited for batch measurement for parts up to 2 metres in size such as blades blisks, turbines, vehicle components etc. It delivers rapid, high accuracy automated 3D measurements. Contained within our environmentally controlled measurement cell, the ScanBox utilises the GOM ATOS 16M Triple Scan sensor, with the ability to capture surface data with a detail resolution of more than 20 measuring points per millimetre.

What level of accuracy can be achieved?

Our 3D Measurement systems are able to capture up to 16 million points within 1-2 seconds. The level of accuracy achieved is often determined by the client and can vary on object size, complexity etc. Typically for a turbine blade we would look to achieve a precision of less than 5 microns.

For example of some of our projects, please see our case study page for more information on the different types of objects we are able to scan.

For all your 3D measurement and Inspection requirements, be it a strawberry, sculpture, jet turbine or industrial gas turbine, contact our experienced team on 01483 750200 or via our contact us page and we will be pleased to help you with your enquiry.

Team BMW title push continues at Oulton Park

Colin Turkington (GBR) WSR BMW

Team BMW continue their push for the title this weekend as Oulton Park in Cheshire takes the British Touring Car Championship to the halfway point of its 2019 season. A second-place finish and three top-six results last time out at Croft propelled Colin Turkington into an 11-point series lead while BMW grabbed the lead of the Manufacturers’ Championship.

With WSR-run Team BMW also holding second place in the Teams’ points table, three-time BTCC champion Colin is aiming for another strong set of performances on the 2.2-mile ‘Island’ layout of the picturesque parkland circuit. Colin, who is aiming for a record-equalling fourth BTCC crown, has two victories this year in the new BMW 330i M Sport and is a seven-time winner at Oulton Park, including doubles in 2009 and 2014.

For WSR, Oulton Park has also been a happy hunting ground. The Sunbury-on-Thames-based team have recorded 36 podiums and 13 wins in 21 years, including an incredible 1-2-3 finish and double-success last year.

Colin’s position at the top of the points means he carries the maximum 54kg success ballast into the weekend, making his 3 Series the heaviest car on the grid.

Team-mate Tom Oliphant is from nearby Tarporley and has a special connection with his local circuit. After equalling his career-best BTCC qualifying result with fifth on the grid at Croft and delivering a strong fifth-place finish in the opening race, he once again showed why he is widely-tipped to become a race winner in his second season in the series.

The Oulton triple-header on June 29-30 is the fifth of 10 events in this year’s BTCC, which takes in eight circuits the length and breadth of the country. Each race will be screened live and exclusively on ITV4 in HD.

Colin Turkington said: “I feel happy with where we are with the 3 Series and the development, so the plan is to go into the summer break with the momentum on our side. Oulton Park incorporates some of the most demanding corners in British motorsport such as Cascades and Druids, which require a lot of commitment, and it’s narrower than most tracks, which enhances the sense of speed. You really need to be on-point if you want to be on the pace. Going there as championship leader obviously presents its own challenges. It won’t be easy on maximum ballast though.”

Tom Oliphant said: “Oulton Park is very much home turf and I always enjoy going there. It’s one of my favourite tracks. It presents a unique challenge as a driver, and qualifying is a lot of fun as you push yourself and the car absolutely to the limit. Grid position is particularly important there, because the narrow track makes it difficult to overtake and you really need to get your elbows out to go forwards but I’ll arrive with no weight in the car, which will definitely be an advantage so I’m focussed on starting right at the front. I’m confident the new BMW 3 Series will feel good. I’ve had some terrible luck recently, so what we need above all else is a clean weekend and three consistent finishes”

Dick Bennetts, Team Principal, said: “Oulton Park has traditionally been a very good circuit for WSR in recent years, but in 2019 the new BMW 330i M Sport has been fast everywhere, so there’s no reason to think we can’t score good points again, provided everybody continues working at the extremely high level we’ve set ourselves. Colin has won here many times in our cars and is always a factor, while Tom grew up near here and is keen to turn his strong qualifying pace into three good results.”

Jordan eyes more success at Oulton Park

Andrew Jordan and BMW Pirtek Racing head to Oulton Park this weekend aiming to maintain their sensational recent British Touring Car Championship form. The Lichfield driver has won more races than anybody else this season – five – including dominant doubles at each of the last two rounds at Thruxton and Croft in his WSR-run BMW 330i M Sport.

The 2013 champion returns to the scene of his maiden BTCC podium optimistic of continuing that run of results at the demanding 2.2-mile Cheshire circuit. His incredible recent run has lifted Andrew to fourth in the Drivers’ Championship – 26 points behind leader and WSR stablemate Colin Turkington, with 67 available this weekend. This means he carries 36kg success ballast into the weekend, which is certain to slow the BMW 3 Series in the numerous uphill traction zones at Oulton.

Andrew has a strong record in the BTCC at Oulton. Since recording his maiden BTCC podium there in 2008, he has added 11 more, including two wins.

For WSR, Oulton Park has also been a happy hunting ground. The Sunbury-on-Thames-based team have recorded 36 podiums and 13 wins in 21 years, including an incredible 1-2-3 finish and double-win last year.

Another triumph this weekend would mean that the Sunbury-on-Thames team’s BMWs have been victorious in six consecutive seasons at the track.

The Oulton triple-header on June 29-30 is the fifth of 10 events in this year’s BTCC, which takes in eight circuits the length and breadth of the country. Each race will be screened live and exclusively on ITV4 in HD.

Andrew Jordan, Driver, BMW Pirtek Racing, said: “Oulton Park has been one of my strongest circuits in recent seasons, and I love it. We need to hold our expectations in-check, but I do go to Oulton expecting to challenge for pole position and race wins – and if we can’t win, we need to keep bagging points. Yes, ballast has a greater effect than at most places, but I’ve won races on full weight this season, so it’s not something I think about. We’ve found the sweet spot with the new 3 Series, and the confidence level is sky-high. I think we are the strongest package on the grid right now, so we need to use that positive momentum to keep moving forwards.”

Dick Bennetts, Team Principal, said: “AJ and the whole team have been in terrific form recently, qualifying well when his car was light, and still being able to succeed when his car’s had full ballast in Race Two. We managed a 1-2-3 finish at Oulton last year with the BMW 1 Series, and the new 3 Series should be a little better-suited to the fast corners here, so even with the ballast he carries, he should be capable of qualifying and racing well.”

Photo credit JEP/BMW.

Shaping the future for 3DSL measurement with Nadcap accreditation

Aerospace Blade Mesh - 3D Scanning

Physical Digital® become first company in the world to receive Nadcap accreditation for Measurement and Inspection using 3D Structured Light (3DSL).

Nadcap recognizes Physical Digital for its commitment to continual improvement in aerospace quality.

We have provided 3DSL measurement services to the Aerospace industry for many years, completing repeatability studies, batch measurement, inspection and analysis on industrial components from single turbine blades to complete jet turbine engines and full aircraft. Our exemplary service has built us a reputation over the years as the leading service provider of 3D Structured Light scanning services within the UK. As a business our company has grown substantially over recent years, and this has allowed us to improve our facilities and refine our business processes to ensure that we continue to deliver the highest level of accuracy and traceability for our customers.

At our facility in Guildford, Surrey, we operate a state-of-the-art metrology facility optimised for 3D optical measurement with environmental monitoring and controls including precise temperature control, diffused airflow distribution, optimised lighting and humidity monitoring to ensure any effects are understood and mitigated.

Physical Digital receive Nadcap accreditation for demonstrating ongoing commitment to quality by satisfying customer requirements and industry specifications.

 

Our Managing Director Tim Rapley commented: “Physical Digital is the first company in the world to achieve a NADCAP accreditation for Measurement and Inspection using 3D Structured Light. Using industry-leading GOM metrology systems, we specialise in capturing high-accuracy surface data for a wide variety of industrial sectors such as Aerospace and Power Generation. All measurement data captured is completed under the rigorous constraints and stringent business processes, with all data traceable back to the international standard. This accreditation is the highest accolade that we could have hoped to achieve as a business and as Managing Director and company founder, it fills me with pride. It is also well-deserved recognition for the hard work and dedication of our highly-skilled and experienced team of Metrologist and Engineers. Achieving a Nadcap accreditation of our 3DSL services will provide our customers with the added assurance that Physical Digital deliver the highest quality data with unprecedented levels of traceability”.

 

“Nadcap accreditation is universally acknowledged as a significant undertaking. Validating compliance to industry standards, best practices and customer requirements, Nadcap has long been incorporated by the aerospace industry into their risk mitigation activity. Congratulations are therefore due to Physical Digital as their hard work has resulted in achieving Nadcap accreditation for Measurement and Inspection using 3D Structured Light and their supporting company Quality Management System,” commented Michael J. Hayward, Executive Vice President and Chief Operating Officer at the Performance Review Institute.

Click here to find out more about our Nadcap Measurement and Inspection services using 3D Structured Light.

About Nadcap: 

Created in 1990 by SAE International, Nadcap is administered by the not-for-profit Performance Review Institute (PRI). PRI is a global provider of customer-focused solutions designed to improve process and product quality by adding value, reducing total cost and promoting collaboration among stakeholders in industries where safety and quality are shared goals. PRI works closely with industry to understand their emerging needs and offers customized solutions in response. Learn more at www.p-r-i.org or contact PRI at PRI@p-r-i.org

Media Contact:

For all media enquiries please contact: Lucy Steer, lucy@physicaldigital.com or +44 (1) 1483 750 200.

Physical Digital® make FSB South East Awards finals!

FSB South East Awards Finalists

Physical Digital celebrate as they make it to the shortlists for the FSB South East Awards for Business and product innovation.

The FSB Awards recognise the best small business right across the UK, from every sector and industry. The category Physical Digital have entered is varied, with many businesses offering unique specialisms making them stand out in their field of expertise. We were recently advised that we have been lucky enough to be selected as finalists for this award, alongside some fantastic other regional businesses, all striving to develop their companies through innovation.

Physical Digital is the UK’s leading supplier of optical measurement using 3D Structured Light (3DSL). We specialise in delivering 3D scanning services to industry, working more specifically within the Aerospace, Power Generation and Automotive industries. Because of the nature of these industries, they command the highest level of accuracy, repeatability and traceability.

Our 3D scanning services capture surface data from a physical object, producing a highly-accurate digital representation. The captured data can then be used for inspection and performance analysis or passed onto our in-house design team for full reverse engineering, which is ideal for legacy product remanufacture.

Our expert team offer the UK’s highest resolution and highest accuracy 3D measurement services to capture the detailed surface data of an object, using the industry leading non-contact optical metrology systems, Physical Digital offer both in-house and on-site, mobile measurement services, providing a flexibility of service to our customers and ensuring that 3D scanning is completed in a timely manner, with the least amount of downtime for operational products as possible.

Over the past 18 months, we have been working towards an industry-respected accreditation for Aerospace called NADCAP, which will provide recognition for our services of the highest-calibre and set us apart from other service providers within the UK. We have recently received NADCAP certification for our Quality Management System and are currently undergoing thorough technical audits for Measurement and Inspection and 3D Structured Light. Once completed, we will be the first business in the world offering 3DSL services accredited to this specific NADCAP standard. To prepare us for this process, our business has undergone some changes including the introduction of a specialist environmentally controlled measurement cell. This managed environment controls lighting and temperature which is fundamental for dimensional metrology. We maintain the standard reference temperature of 20° according to the International standard. This constant temperature reduces the thermal expansion of materials, ensuring the highest level of accuracy is achieved.

To find out more about our measurement services, see the dedicated service pages on our website:

3D Scanning

Automated measurement

Quality Inspection

Reverse Engineering

Design

 

Looking forward to the final!

We are very much looking forward to the FSB South East Awards final, which is being held at on the 12th April 2019. Take a look at the companies who join us as finalists within the Business and Product Innovation category:

Snowy’s canine therapy centre Ltd

Inner-vision Technology Ltd

J Randalls

Crumbs Brewing

Spring has sprung at Physical Digital

Daffodil 3D scanning phase-shifting fringe pattern

Here at Physical Digital® we thought we would celebrate the start of Spring by capturing the beauty of the daffodil by 3D scanning one. 3D scanning a flower is not usually a request we would receive so we thought it would be fun to use our high-resolution and high-accuracy GOM optical measurement equipment to capture the delicate nature of a daffodil and the results are simply stunning!

3D scanning a flower

We started the process by creating a fixture on which to place the Daffodil for 3D scanning within our automated measurement cell, the GOM ATOS ScanBox. The fixture increases process stability for measurement and allows for repeatable scans in a fixed position within the scan volume, while also allowing the maximum optical access across the whole surface of the flower.

The volume used to complete the 3D scan was 170 measurement volume which is the highest resolution and suitable for the size of the Daffodil. Measurement volumes can be adjusted to suit the required detail and resolution needed for size of the object being captured, and the level of accuracy required for the project.

Using 3D Structured Light (3DSL), our non-contact optical scanner projects a phase-shifting fringe pattern onto the object in order to capture the full-surface data. Once complete, a polygon mesh is produced by the specialist inbuilt software. This high-resolution polygon mesh can be exported as an .STL file which can be used for further inspection and analysis. The data can also be used to 3D print the object or it can be passed onto our in-house design team for full reverse engineering for remanufacture, ideally suited to legacy products where the CAD model is not available for reproduction.

The data captured for this example perfectly showcases the intricate detail that our industry-leading non-contact optical measurement systems can capture.

As you can see from the images, the veins on the delicate petals on the Daffodil are clearly visible. The non-contact aspect of our GOM metrology systems allow us to capture precious surface information without jeopardising the integrity of the object. This has proved particularly useful for historical artefacts and is why we are the preferred supplier of 3D scanning and inspection for major Aerospace OEM’s, where the freeform shapes are inherently difficult to capture but required where component integrity is critical.

For more information on how Physical Digital’s non-contact, high-accuracy 3D scanning and reverse engineering services can support your project, contact us today for more information or take a look at our website for more information on our services:

www.physicaldigital.com

What is Laser Scanning?

Laser Scanning - 3D optical scanning phase shifting fringe pattern

What is Laser scanning?

Laser stands for Light Amplification by the Stimulated Emission of Radiation. 3D laser scanning uses a laser beam to scan parts. There are various types of laser scanners, but the most commonly used are: handheld, where the beam sweeps over the part and tripod mounted, where the laser line sweeps across an area or measures a single point. The scanners can also be attached to an arm or traditional CMM gantry, however this sometimes limits scanning to a finite size, which can increase the risk of human error and introduce a level of uncertainty to the measurement.

3D Structured Light (3DSL) scanning

3D scanning using structured light is a fast, highly-accurate and non-destructive method of capturing the physical form of an object digitally. Much like laser scanning, the digital data captured via 3DSL scanning can then be used in product design, visualisation and inspection to assist design engineers with quality assurance, design modifications and improvements.

Rather than using a laser beam, 3DSL optical scanning uses two high resolution digital cameras in order to capture the data. A digital projector and Light Emitting Diode (LED) project a fringe pattern across the surface of the object using a narrow wavelength of blue light. By using the two digital cameras and applying the principles of triangulation, the sensor measures to a very high level of accuracy. This creates a high-density point cloud of surface measurements which can be used for a wide variety of applications.

Data output

Both laser scanners and 3DSL scanners produce high-density point clouds or polygon mesh which can be inspected directly to a CAD model, geometry or manufacturing drawings or, for legacy products can be reverse engineered using specialist software.

Accuracy and traceability

Laser scanners capture the data once as the line passes the illuminated object.  3DSL scanners sample the data many times, as fringe patterns of blue light of varying width and phase capture the form of the object. Due to the repeatability, traceability and high- resolution of measurement, the accuracy of a 3DSL scanner is described as inherently higher than that of a laser scanner. Both systems are largely unaffected by the ambient light conditions, making either type of system suitable in industrial applications. Due to the higher level of accuracy afforded by 3DSL scanning, it is particularly suitable for measuring very detailed items, capturing defined edges of parts such as turbine blades. For this reason, 3DSL is the preferred method of data capture for Aerospace and Power Generation industries due to the high-level of accuracy, resolution and full traceability of the data.

Safety

One of the big differences between Laser scanners and 3DSL (blue light) scanners is the intensity of light used. Laser scanners focus intense light and energy into a very small area and therefore one of the largest safety concerns around this is eye-safety. Blue light technology does not project with the same intensity, and therefore does not present the same risks. This makes the 3DSL technology easy to implement in a wide range of environments as it presents minimal safety issues when being used in open workshops or design studios.

Potential Scanning Area

The potential scanning area of the GOM ATOS system we use at Physical Digital can be extended without impacting on the accuracy of the scan data through the added benefit of using the GOM TRITOP photogrammetry system.  Photogrammetry is a separate metrology system designed to capture reference points using multiple digital images, using a verified DSLR camera.  The GOM system can use these reference points to extend the potential scanning area, which means it is possible to capture large objects such as entire aircraft or boats.  The majority of laser scanners do not have the ability to integrate with photogrammetry or other single point systems such as laser trackers, meaning that the accuracy when scanning larger objects can be compromised.

Physical Digital are the UK’s leading provider of 3DSL Scanning

As the UK’s leading service provider for 3D scanning metrology and reverse engineering, Physical Digital have invested heavily in the industry-leading GOM metrology system which uses 3DSL as its method of data capture. Physical Digital maintain the highest level of industry calibration and traceability for all their GOM metrology systems and where required utilise the GOM photogrammetry systems with traceable artefacts of less than <1µm uncertainty.

The 3D scanning systems used by Physical Digital record all measurement data within its dedicated specialist software. This allows vital information to be recalled at any time, such as calibration information, measurement temperature, part numbers and lighting or movement changes, along with maintaining a fully parametric link from measurement data to final report. This offers a huge advantage over every other system currently on the market and provides the full traceability required for high liability manufacturing.

Our GOM ATOS Triple Scan and Compact Scanning systems are fully mobile enabling our expert team to complete measurement at your facility, reducing the downtime of your production parts. For repeat and batch measurement projects, our automated ATOS ScanBox is the ideal solution, providing highly accurate and cost-effective data capture for larger projects.

BMW and WSR bring 3 Series back to BTCC

BMW 3 series_Photo credit Nick Moss Design

The most successful model in the history of touring car racing, the BMW 3 Series, will make a spectacular return to the British Touring Car Championship in 2019 with Team BMW and BMW Pirtek Racing.

Three examples of the 330i M Sport will be driven by Colin Turkington, Tom Oliphant and Andrew Jordan and run by reigning champion team WSR, who have designed and built the race car around the new seventh-generation model.

The 3 Series has won major championships on every continent including five Drivers’ titles and two Manufacturers’ crowns in the BTCC between 1988 and 2009 and gained iconic status as one of motor racing’s greatest cars.

Sunbury-on-Thames-based WSR began its ultra-successful relationship with BMW with the fifth-generation 320si in 2007.

Winning the Independent Drivers’ and Teams’ titles for three consecutive years, the team achieved a first outright BTCC crown in 2009 with Colin Turkington netting the Drivers’ championship at a dramatic Brands Hatch season finale.

Stephen Jelley, Rob Collard and Tom Onslow-Cole all contributed to 19 victories while WSR and Colin also claimed a win in the FIA World Touring Car Championship with the model.

The 330i M Sport replaces the 125i M Sport, which has been the most successful car in WSR’s history.

Debuted in 2013, it propelled Colin to two Drivers’ championships as well as taking four Teams’ titles, three Manufacturers’/Constructors’ crowns, 36 race wins and 116 podium finishes.

The new BTCC season starts at the legendary Brands Hatch circuit in Kent on April 6-7, with the 330i M Sport set to appear for the first time in public at the same circuit at the series’ Media Day on March 27.

 

Dick Bennetts, Team Principal, said: “We are really pleased to be bringing the BMW 3 Series back to the BTCC. We achieved a great deal of success with the fifth-generation model between 2007 and 2012, so we are hugely excited to see what the latest version is capable of. A lot of hard work and countless hours lie ahead, but we are all confident of turning this car into a winner and hopefully reinstating it in its rightful place – at the front of the field in Britain’s premier motorsport series.”

 

Graeme Grieve, CEO, BMW UK, said: “The BMW 3 Series has a rich and successful history competing in the BTCC and we are extremely proud to see that tradition continue. This all-new BMW 3 Series is the road-going dynamic benchmark and we have a great track record working with our partners at West Surrey Racing, so 2019 looks set to be a very exciting year for us in the BTCC.”

 

Image information
All images show a graphical rendering of the BMW 330i to be raced by Team BMW and BMW Pirtek Racing in the 2019 British Touring Car Championship. Photo credit Nick Moss Design.

Press release credit: West Surrey Racing.

For media enquiries relating to WSR, including image requests, please contact Jamie O’Leary (+44 7725 087316 or jamie@topstepcommunications.co.uk).

For media enquiries relating to Physical Digital®, please contact Lucy Steer.

Best of British are back!

Ben Murphy The Blades Racing Team

Pilot Ben Murphy and the Blades Racing Team kick off 2019 World Championship this weekend

3D scanning company Physical Digital® continue to support The Blades Racing Team as Technical Partners, as they enter the start of their second Red Bull Air Race World Championship.

Just one year ago, British pilot Ben Murphy and the Blades Racing Team were making their debut in the Red Bull Air Race World Championship with an astonishing sixth-place performance at the 2018 opener in Abu Dhabi. The effort jump-started what turned out to be the best rookie season ever delivered by a graduate of the sport’s exclusive feeder class. On 8-9 February, Murphy will race over Abu Dhabi’s Corniche once again, launching a brand-new season that holds strong promise for his
first race podium.

 

With experience as a former Team Leader of the Red Arrows, and an exceptionally dynamic team behind him, anticipation for Murphy’s premiere season had been high among Britain’s aviation and motorsport fans last year. But the Blades’ accomplishments exceeded all expectations: no Race Day pylon hits, advancements to the Round of 8 in over 60 percent of their races, an impressive 29 World Championship points and a final placement in the top half of the field at seventh overall. Perhaps most indicative of their rapid progress were two consecutive advancements to the Final 4 to close the calendar, with Murphy finishing just a tenth of a second off the podium at the November season finale.

Acknowledging that missing the race podium by such a small margin has made him “even hungrier,” Murphy will be looking to accelerate his 2018 momentum with a strong result in Abu Dhabi on Friday and Saturday. All season long he will be joined by the same outstanding team members: Team Principal Andy Offer, Team Manager Rebecca Allen, Tactician Neil Furness, Technician Andreas Kaufmann and Team Coordinator Annie Stone. In addition, the Blades Racing Team remains in partnership with their longstanding and highly supportive sponsors, Aerobytes, Zyrad Cables and the RAF Benevolent Fund. With a full year of collaboration and experience under their belt, they have become a tight unit, determined to build on their initial successes for continued progression. Throughout the eight-race 2019 season, the Blades Racing Team will be working to refine their processes and squeeze even more performance out of their raceplane. They will also be covering the globe with more ease and efficiency than ever, thanks to a new partnership with OGIO.

“We’re continuously reviewing every detail of how we operate this year, even more so now that we have teamed up with OGIO to supply the team’s luggage to improve how we travel and get kit to and from locations,” Murphy says. “It’s just another example of how, on every level, our goal this season is to get better.”

See Britain’s only Red Bull Air Race team soar into the 2019 season. For ticket information and all the latest news on the World Championship, visit www.redbullairrace.com.

Red Bull Air Race 2019 Calendar
8-9 February: Abu Dhabi, UAE
TBA: Europe
15-16 June: Kazan, Russia
13-14 July: Budapest, Hungary
7-8 September: Chiba, Japan
TBA: Asia
19-20 October: Indianapolis, USA
8-9 November: Saudi Arabia

About Red Bull Air Race

The Red Bull Air Race World Championship is an aerial motorsport series that demands a combination of speed, precision and skill. Using the fastest, most agile, high performance race planes, pilots compete in iconic locations over water and land. The high speed, low altitude and extreme manoeuvrability required make it accessible only to the world’s most exceptional pilots. Flying just metres from the ground, 14 Master Class pilots race against the clock whilst reaching speeds of up to 370 km/h, requiring a combination of precision and skill unmatched in the world of aviation. Pilots must be in peak physical condition as they endure forces up to 12G while navigating the technical racetracks made up of air-filled pylons.

The Air Race was developed in 2003 and is accredited by the Fédération Aéronautique Internationale (FAI), with more than 90 races completed across five continents. As the most advanced aerial challenge in existence, competing in the Red Bull Air Race World Championship is the highest accolade for elite pilots.

A Challenger Cup feeder series was introduced in 2014 with the goal of facilitating the development of the unique skills required for the Master Class for the next generation of pilots.

For more editorial content, visit www.redbullairracenewsroom.com.

What is Reverse Engineering?

What is Reverse Engineering? Physical Digital Reverse Engineering Services

It is a very common question asked, what is reverse engineering?

In mechanical engineering, the term reverse engineering (often abbreviated to RE) is used to summarise the process of reconstructing an existing object. When designing an object from scratch, an engineer will draw up a design specification and produce drawings from which the item is constructed.

Conversely, with reverse engineering, the design engineer starts with the final product and works through the design process in the opposite direction to arrive at the product design specification. During the process, vital information about the design concept and manufacturing methods is discovered.

The process of reverse engineering begins by gaining dimensional information of the object via 3D scanning, whether it is a mechanical component, a consumer product or an ancient artefact.

Reverse engineering involves acquiring three-dimensional positional data in the point cloud. There are many ways of gathering valuable dimensional information about the product, but using an accurate 3D measuring system is paramount. The accuracy of the data captured will impact the quality and deviation of the Reverse Engineered model when compared to the original.

Physical Digital uses the globally-recognised GOM 3D structured light scanning systems, which offer highly-accurate, traceable and repeatable measurement. The surface data captured is then passed to our in-house design team to establish the original design intent of the object.

What is Reverse Engineering used for?

Reverse engineering enables the duplication of an existing part by capturing the component’s physical dimensions, features, and material properties. There are a wide range of reasons for reverse engineering an object, including:

Legacy Components – For many components that were designed and manufactured years ago, there are no existing 2D drawings or 3D CAD data from which to reproduce the object. Here, reverse engineering is a vital means to gain the information to recreate the product.

Original Equipment Manufacturer (OEM) issues – If the OEM is no longer trading or has lost design measurements, then Reverse Engineering will supply the vital product information to continue manufacturing of that object.

Design Development, Part Testing & Analysis – Through reverse engineering, a 3D product can be quickly captured in digital form and remodelled or analysed in order to achieve improved design iterations.

Competitor Analysis – Any organisation can analyse competitor products through reverse engineering.

Bespoke and Ancient objects – Where there is no information about the dimensions of an object except for the physical item itself, the quickest and most reliable way to reproduce it will be by reverse engineering. Where a product is organic in shape (not a standard geometry such as cuboid or cylindrical), designing in CAD may be challenging as it can be difficult to ensure that the CAD model will be acceptably close to the sculpted model. Reverse engineering avoids this problem as the physical model is the source of the information for the CAD model.

Modern manufacturing – methods such as Additive Manufacturing rely on reverse engineering.

Digital Archiving – Museum pieces and historic artefacts can be captured through 3D scanning, then reverse engineered and the resulting CAD data can be held in case of any future damage to the object or any need to reproduce parts of the item.

 

Time and cost-effective way to produce models and products

The process of reverse engineering is particularly cost effective if the items to be reverse engineered represent a significant financial investment or will be reproduced in large quantities. Another advantage presented by reverse engineering is in compressing the product development cycle. In a highly competitive global market, manufacturers constantly strive to shorten lead-times to bring a new product to market. With reverse engineering, a 3D model can be quickly captured in digital form and remodelled if necessary or exported for a variety of manufacturing methods such as Additive Manufacturing, Vacuum Casting or CNC machining.

How to capture the data for Reverse Engineering 

Representing the geometry of the part in terms of surface points is the first step in creating parametric or free-form surfaces. A highly accurate and dense polygon mesh is created from the point cloud using the native measurement software or a dedicated reverse engineering software.

The added benefit of a photogrammetry system provides even greater certainty of the data captured for larger objects, such as entire aircraft or boats. Photogrammetry is a separate metrology system designed to capture reference points using multiple digital images, using a verified DSLR camera. The GOM 3D scanning system can use these reference points to extend the potential scanning area, which means it is possible to capture larger items, which can then be reverse engineered.

Reverse engineering process

Depending on the downstream application for the CAD model, different types of surfaces can be created. For example, this could range from producing a fully parametric CAD model which can be easily modified, which is likely to be required when undertaking redesign or optimisation. Compared to where the part is going to be remanufactured or analysed, when a clean representation could be employed.

Through the use of inspection software, analysis of the CAD model is performed and reported to the Client. This highlights the maximum deviations between the scan data and CAD model and documents that the requirements of the specification have been met.

Why do we use Computer Aided Design (CAD)? 

Through the use of various CAD and reverse engineering software, we can create accurate data for manufacturing, analyse how it will perform and improve existing designs.

CAD is used to create two- or three-dimensional (2D or 3D) graphical representations of physical objects. In product and industrial design, CAD is used mainly for the creation of detailed 3D solid or surface models, or 2D vector-based drawings of physical components. However, CAD is also used throughout the engineering process from conceptual design and layout of products, through strength and dynamic analysis of assemblies, to the definition of manufacturing methods. This allows an engineer to analyse design variants, to find the optimal design for manufacturing while minimising the use of physical prototypes