A 3D-Object Reconstruction System Integrating Range-Image Processing and Rapid Prototyping

This paper describes a system which integrates computer vision and rapid manufacturing technologies to scan physical objects and to replicate the reconstructed shapes as steel faced dies using shaping deposition processes. A light-atripe range finder is used to scan t,he 3-D data of the object. Range data is then processed in order to generate a solid model representation. A simulation process is incorporated to display the reconstructed object so that data quality is checked and refined before proceeding to the fabrication process, as well as viewing object in alternative materials and colors. The computer model is then replicated as a plastic prototype with stereolithography. Finally, this prototype is used as a pattern in a thermal spray process to build a metal-faced die replica of the original object. The system is demonstrated by scanning a human face which is then replicated as a stainless-steel sculpture.