Efficiently design and engineer plastic parts

The challenge

Plastic parts are becoming ever more complex and manufacturing tolerances increasingly strict. At the same time, time pressure is increasing. This makes fast yet reliable design and function validation at the prototype stage all the more important. High-precision measurement data is required for this.

Our solution

With 3D scanners and CT systems from ZEISS, you can quickly create a detailed image of the prototype. The entire surface is reliably captured – including boreholes, undercuts, angled edges and freeform surfaces. CT measurements also digitize the inside of the part. You can use the measurement data to create design data (reverse engineering), perform nominal-actual comparisons, adjust part and tool geometries in existing CAD data and verify assembly capability.

The challenge

Some plastic parts can only be accurately digitized with the use of fixtures, such as those with complex shapes or high elasticity. However, the production of fixtures is time-consuming and expensive.

Our solution

Integrated into the ZEISS INSPECT metrology software is the Virtual Clamping module, which simulates the clamping of parts. In this way, the clamped state can be calculated using the data of the real part in the unclamped state. Fixtures are no longer required. You get reliable inspection results that are significantly less influenced by the operator and allow for higher repeatability.

The challenge

Measurement processes should be accelerated. In addition, inspection data should be available throughout the entire product lifecycle management (PLM), so that continuous control via centralized part management is guaranteed.

Our solution

When Geometric Dimensioning and Tolerancing (GD&T) is integrated into the CAD model via PMI according to standards and inspection requirements, 3D measurement planning and inspection can be performed directly on the PMI data set (import and evaluation of FTA/MBD data).

The PMI can be imported into the PMI metrology software CALYPSO and ZEISS INSPECT, accelerating product development and production processes.

The challenge

Prototypes of plastic parts need to be converted into complete and consistent CAD models.

Our solution

Scan a part in ZEISS INSPECT Optical 3D or other software and import the STL or PLY data and ASCII formats into the ZEISS REVERSE ENGINEERING software. In just a few guided steps, you can create a highly accurate CAD model that you can export in popular formats such as IGES, STEP, or SAT.

The challenge

During injection molding, the part shrinks and deforms. The resulting part defects are due to a wide variety of influencing variables that are interdependent. This makes tool compensation extremely challenging. The tool is often optimized by trial and error.

Our solution

Simply import three sets of data into the ZEISS REVERSE ENGINEERING software – the existing CAD data of the tool and plastic part, and the actual measuring data of the part – and use the software to identify and optimize the areas to be corrected. The software only suggests changes that work in practice. This allows the software to account for the fact that corrected tool geometries can be eroded and the parts can be demolded.

The challenge

Plastic parts are subjected to strength analyses, vibration analyses and high cycle fatigue strength tests. The measuring results are used to determine product durability or load limits and to optimize geometry layout. The measurement of each parameter with individual sensors and the subsequent evaluation is very complex.

Our solution

The optical 3D measuring system ARAMIS captures the real part geometry including the non-linear deformation behavior during load testing and allows a direct comparison with the FEM data. The measuring system provides a dense mesh of easily interpretable data that offers both full-field and point-based analysis options.