1854 Cycling Company Bike Frame Scan

 

Background:

1854 Cycling Company is a startup created by Brandale Randolph, who came to the 3DExperience Fab Lab while I was on coop at Dassault Systemes. 1854 Cycling Company creates electric motorized and pedal assist bicycles. 

Problem:

1854 Cycling was looking to update their motor housing unit CAD model for a new bike frame for a new Bosch Motor. The manufacturing of the housing unit refused to share the dimensions and CAD models with Brandale.

 

Brandale came to the 3DExperience Lab to use a 3D scanner to create an STL of the bike frame. 

 

The STL needs to accurate to the bike frame sizes and dimensions because 1854 designer will be adjusting the new housing from these dimensions. 

 

New Bosch Motor to put into updated Frame

HandyScan tested on wrench

HandyScan tested on wrench

Actions

A Creaform HandyScan 3D in combination with VXElements were used to create a STL of the model. Over the course of a few weeks, the bike frame was split into section and slowly scanned into the software.

 

To scan, the bike frame was placed vertically and horiztonally and covered in calibration targets. I then carefully moved around the surface in order to capture. 

 

These scanned mesh was manupulated using VXElements to create a more detailed scan and fill in any holes in the mesh.

Problems and Solutions

Problem: Black carbon fiber bike frame would not scan properly and included many holes in the mesh. Creaform struggles with darker images.

Solution: VXElements settings were tweaked to allow for darker color surface. The sensor allowed for less reflection of the surface because of darker surface

 

Problem: VXElements meshing incorrectly and with not enough detail for best outcome.

Solution: Mesh values were carefully tuned with some research into optimal settings from Creaform. 

 

1854 Bike Carbon Fiber frame from website

Bike Frame STL Front Side

Bike Frame STL Back Side

Results:

Created an accurate STL with focus on battery and motor housing location. Handed off STL to Brandale for designer to update CAD.

 

 

Personal Growth:

Learned how to use new software for realistic scans and meshs

Developed problem-solving and research skills for new software

Patience.