A method of machining a cellular core (14) includes mounting the core (14) atop a table (12) in a multi-axis Computerized Numerical Controlled (CNC) machine (10). The machine (10) is operated to self-scan the core (14) and self-recognize individual cells (30) arranged laterally in columns and longitudinally in rows. A machining path (E) is self-generated from the pre-recognized cells (30), and the core (14) is then machined along the self-generated machining path (E).

A robotic system is presented that includes a surface inspection system that receives sampling information for a number of areas within a region of a worksurface. The system also includes a robotic arm, coupled to a surface engaging tool, the robotic repair arm being configured to cause the surface processing tool to engage the region of the worksurface. The system also includes a process mapping system configured to, based on the sampling information: approximate a surface topography in the region of the worksurface, generate a surface processing plan for the region based on the approximated surface topography that includes a trajectory. The surface processing plan includes one of: a force profile along the trajectory, a velocity profile for the surface engaging tool along the trajectory, a rotational speed profile, for the surface engaging tool, along the trajectory, or a trajectory modification that accounts for the presence of a surface feature identified in the approximated surface topography. The process mapping system is also configured to generate a control signal for the robotic arm that includes the surface processing plan.

A method comprising scanning a first painted surface of a first vehicle having two or more paint layers with a robotic terahertz radiation instrument to obtain a first painted surface thickness data and map for each of the two or more paint layers, comparing the first thickness map to a control map, and adjusting one or more paint application parameters based on a comparison of the first thickness map with the control map for painting a second surface of a second vehicle different than the first vehicle.

A method of making an arch support for an article of footwear at a kiosk includes scanning a foot of a customer who has selected a shoe for purchase, determining dimensions of the customer's foot based on the scan, comparing the dimensions of the customer's foot with pre-determined dimensions of a last used to make the selected shoe, defining a shape characterized by the difference between the dimensions of the customer's foot and the dimensions of the last, and printing the arch support with a 3D printer. The arch support has the shape characterized by the difference between the dimensions of the customer's foot and the dimensions of the last.

A method for modeling a working environment of a robot comprising providing a robot having a base, a reference point, a plurality of links by which the reference point is movably connected to the base, and sensors for detecting positions of or angles between the links, providing a controller adapted to associate a position of the reference point to detected positions or angles between of the links, installing the base in a working environment which is delimited by at least one surface, moving the reference point to at least one sample point of the at least one surface, determining the position of the sample point from positions of or angles between the links detected while the reference point is at the sample point, and inferring the position of the surface from the determined position.

Examples of providing feedback regarding a scan of a three-dimensional object are described. In one example, a method of computer modeling a three-dimensional object includes computer-tracking a three-dimensional pose of a scanning device relative to the three-dimensional object as the three-dimensional pose of the scanning devices changes to measure different contours of the three-dimensional object from different vantage points, and assessing a sufficiency of contour measurements from one or more of the different vantage points based on measurements received from the scanning device. The example method further includes providing haptic feedback, via a haptic output device, indicating the sufficiency of contour measurements corresponding to a current three-dimensional pose of the scanning device.

Systems and methods of measuring feet and designing and creating orthopedic inserts are described. A leg length discrepancy of a user is measured and this data, along with foot size are input into a computer. The computer then creates a computer model of a custom shoe insert based on this information. The computer model is then sent to a 3D printer to print the insert. The insert consists of a base insert with partial correction, and several additional layers that are added successively over time until a full correction is obtained. This eliminates any pain associated with a fully corrective insert, and allows the body to adjust gradually to the correction.

Systems and methods of inspecting a manufactured part include creating a computer model of the part with a desired model contour having a model feature at a desired location. The manufactured part is scanned to obtain scanned data indicative of a manufactured surface formed in a manufactured contour and having a manufactured feature at an actual location on the manufactured surface. The computer model is modified using modeled reaction forces so that the model contour matches the manufactured surface. A determination whether the manufactured part is acceptable is based on a comparison of the actual location of the manufactured feature with and the desired location of the model feature with the model surface in the modified model contour. Additionally or alternatively, the reaction forces are compared with a reaction force threshold to determine whether the manufactured part requires reworking.

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.

Every junction part for an airplane wing is manufactured with overmaterial. Each part is measured with a laser based interferometer or other scanning technique and the as built measurements are compared with a model to generate a new trajectory milling program to fill or prevent gaps between parts using a points cloud and B-Spline algorithm to generate a new surface to be milled. Once the program is generated (new trajectories) and post processed, it is sent to a milling machine to perform overmaterial milling on already milled parts with overmaterial. This technique can be used to eliminate gaps between junction parts and the corresponding need for shims.