Novel 3-D free-form surface profilometry for reverse engineering

This article proposes an innovative 3-D surface contouring approach for automatic and accurate free-form surface reconstruction using a sensor integration concept. The study addresses a critical problem in accurate measurement of free-form surfaces by developing an automatic reconstruction approach. Unacceptable measuring accuracy issues are mainly due to the errors arising from the use of inadequate measuring strategies, ending up with inaccurate digitised data and costly post-data processing in Reverse Engineering (RE). This article is thus aimed to develop automatic digitising strategies for ensuring surface reconstruction efficiency, as well as accuracy. The developed approach consists of two main stages, namely the rapid shape identification (RSI) and the automated laser scanning (ALS) for completing 3-D surface profilometry. This developed approach effectively utilises the advantages of on-line geometric information to evaluate the degree of satisfaction of user-defined digitising accuracy under a triangular topological patch. An industrial case study was used to attest the feasibility of the approach.