A first surface of a part is scanned with a laser scanner as a platform of a computer numerical controlled (CNC) gantry tool moves relative to the part to form scan data, in which the laser scanner is connected to the platform of the computer numerical controlled (CNC) gantry tool. Differences between the first surface and design for the first surface are determined using the scan data.

A system for process control of a composite fabrication process comprises an automated composite placement head, a vision system, and a computer system. The automated composite placement head is configured to lay down composite material. The vision system is connected to the automated composite placement head and configured to produce image data during an inspection of the composite material, wherein the inspection takes place at least one of during or after laying down the composite material. The computer system is configured to identify inconsistencies in the composite material visible within the image data, and make a number of metrology decisions based on the inconsistencies.

In one embodiment there is a computer numerical control machine implementing a method for measuring and digitizing a cylinder head combustion chamber using a touch probe, wherein the cylinder head combustion chamber includes an intake valve and an exhaust valve. The method includes receiving combustion chamber characteristics of the cylinder head combustion chamber. The method includes receiving probe measurement variables that describe how the touch probe measures the cylinder head combustion chamber. The method includes generating probe measurement lines for each portion of the cylinder head combustion chamber using the combustion chamber characteristics and the probe measurement variables. The method includes measuring, using the touch probe, probe measurement planes for each portion of the cylinder head combustion chamber using the probe measurement lines to generate probe measurements. The method includes digitizing the probe measurement planes for each portion of the cylinder head combustion chamber using the probe measurements.

Systems, methods, and apparatus are disclosed for machining a part. The methods may include generating a plurality of spatial representations associated with a plurality of positions identified by a machining pattern associated with the part. The plurality of spatial representations may include a first spatial representation identifying a first orientation of a machining tool relative to the part at a first position. The methods may include moving an end effector to the first position. The methods may include mechanically coupling, using a coupling tool, the end effector to the part at the first position. The methods may include generating a second spatial representation identifying a second orientation of the machining tool relative to the part at the first position. The methods may include adjusting the machining tool in response to determining that the second spatial representation is different than the first spatial representation.

A method and system provide for reducing gaps between two mating parts. Either or both parts may be nondestructively inspected at a plurality of locations on a surface to gather a data set relating to the part thickness. The data set may be used to calculate a set of as-built thickness values for the part and a set of deviations from a design model. A mating area may be determined for mating surfaces of the parts. One or more layers of sacrificial material in the mating area may be prepared for any deviations greater than a design allowance. The system may include a ply cutting device and an additive manufacturing device coupled to a computer to receive the sacrificial material layer data and shim data and to cut the one or more layers of sacrificial material and to construct the shim. A shim may be constructed for any deviations equal to or greater than a minimum shim thickness. The one or more layers of sacrificial material may be applied to the part, cured, and machined to a desired thickness. The shim may be applied between the part surfaces. The parts may be fitted and assembled together.

Producing a component having an in use gas washed surface includes: obtaining a reference component having a reference shape with an in use gas washed surface; setting one or more performance threshold for the reference shape, the threshold defining an acceptable performance for the reference shape; obtaining a manufactured component made to the reference shape; measuring the manufactured component and determining a displacement distribution indicative of the geometric deviation of the manufactured component from the reference shape; determining a performance sensitivity distribution for the reference component, the sensitivity distribution having a plurality of points, each point indicative of a performance factor for the reference component; combining the sensitivity distribution and displacement distribution to determine a performance prediction for the manufactured component; determining whether the performance prediction is within the performance threshold; accepting or rejecting the component for use if the predicted performance is within or outside the performance threshold, respectively.

A gyroscope-based system and method is disclosed. Image information data is collected; a mechanical arm working environment image is modeled; a heat source supply apparatus and a gyroscope are provided at the mechanical arm proximal end; the position of the proximal end is accurately measured by accurately tracking the heat source at the proximal end; the relative position of the mechanical arm distal end is accurately calculated by using high-precision angle information measured by the high-precision gyroscope in combination with a number-theoretic formula. The disclosure provides separately determining the position of the distal end, or for assisting other algorithms or apparatuses that track the position of the mechanical arm distal end in error correction and calibration of the position of the mechanical arm distal end. The position of the mechanical arm distal end can be continuously and dynamically tracked in real time, and virtualized in the corresponding image system.

This disclosure relates to a computer-implemented system and related methods for the design, evaluation, and/or manufacture of protective patient footwear, such as shoes, braces, boots, casts, corrective footwear, and orthoses. The system includes suitable hardware, software, and related peripherals, which function to acquire data related to the patient's particular footwear needs, such as by image capture, including three-dimensional scanning. The system may also acquire data through other sources of input, such as through one or more sensors for detecting various physiologic parameters associated with the lower extremity, or through input of medical conditions, prior indicators, exam, analysis, lab results, or the like, such as through medical practitioner input or other input protocols. The various inputs may be suitably processed to generate output in the form of a design accommodation to design or modify the protective patient footwear, or in the form of one or more medical evaluations or recommendations.

A custom foot orthotic and a system and a method for designing of a custom foot orthotic. The method includes: receiving 3D scan data of the patient's foot; receiving plantar pressure scan data of the patient's foot; establishing a desirable pressure distribution; generating an underfoot elevation profile relative to an elevation profile of the patient's foot in the 3D scan data; determining an internal density profile of the resulting foot orthotic 3D model by superimposing the desirable pressure distribution over the resulting foot orthotic 3D model and reducing or increasing density in regions of the foot orthotic 3D model based on the difference between an expected pattern of support and the desirable pressure distribution; and outputting the 3D model of the custom foot orthotic.

A system and method that relies on the principles of material science, deformable body mechanics, continuum mechanics and additive manufacturing to reduce the costs associated with additive manufacturing. Physical properties are used by numerical solution methods, such as the Finite Element Method (FEM) or Smooth Particle Hydrodynamics (SPH), to deform an original model of an object to be manufactured into a viable configuration that reduces fabrication material, time, and cost when manufacturing an object through additive manufacturing.