Dimensional Measurement Blog

Bluing and scribing of castings (also known as casting layout) is a tried-and-true method for dimensional inspection of a metal part made typically by sand casting or permanent mold. By placing the dimensions from a drawing on to the actual part, you can determine whether it meets the specifications. Although this method has been used for decades, new technologies have effectively superseded the need for it in most cases.

For example, 3D scanning can be used to superimpose points on a 3D model with a corresponding profile and dimensional analysis to show deviations from the drawing as well as quantify them. Of course, like any technology, even the most advanced systems come with pros and cons. With new options that are faster and more accurate, it makes sense to ask why we are still bluing and scribing castings.

Advantages of Bluing and Scribing Castings

Even though it is an older technology, bluing and scribing continues to offer several advantages:

1. Proof of inspection - Unlike a digital scan that leaves no trace, bluing and scribing creates an obvious indicator that the part has been inspected. This can be useful during quality control procedures to ensure that parts have been inspected.
2. Visualization - Bluing and scribing allows you to see whether a part matches the drawing or not, sometimes quickly after the procedure has been completed. And if it doesn't match, it's easy to see what direction the error is in.
3. Tradition - Bluing and scribing is a traditional dimensional inspection method that many seasoned professionals are comfortable with. Changing approaches can be intimidating, but adding new technologies to traditional ones can generate even better results.

Disadvantages of Bluing and Scribing Castings

Advances in technology have illuminated some inherent disadvantages to bluing and scribing that may not have been as noticeable in the past:

1. Speed - Despite its advantages, bluing and scribing takes time, more than with alternative methods such as CMM and 3D scanning. For applications such as first article inspection, when time is of the essence, more modern approaches may be more appropriate.
2. Cost - Bluing and scribing can be expensive when compared with other technologies, especially when you factor in the time is takes to do it.
3. Accuracy - 3D scanners and CMM technology provide more accurate results than bluing and scribing castings, and the subsequent dynamic graphical results are easier to evaluate.
4. Record keeping - With a blue and scribe layout, when the part is returned to the customer along with an inspection report, so are the visualization results: They are on the casting itself. With 3D scanning, a virtual part is retained on file for proper record keeping. This is particularly useful when the customer has questions about the results.

If you are looking for a provider that can offer both traditional and cutting-edge dimensional inspection services, get in touch with Q-PLUS Labs today. We'll help you evaluate your needs for each specific application and recommend a balanced approach that meets the necessary requirements in the most cost-effective manner.

Even though we now have more advanced technology, what do you think about bluing and scribing castings?

3D scanning can be used for multiple reasons, including first article inspection, reverse engineering, and other types of measurement applications. The purpose of 3D scanning is to collect data points to create a digital representation of the object. These data points can be gathered using lasers, white light, contact sensors, and other methods depending on the characteristics of the object being measured.

Although the objective behind the technologies are similar (obtaining measurement data), not all 3D scanning equipment is the same. For example, some equipment gathers data by coming into contact with the object, while others use non-contact optical technology to collect measurements.

Four Factors for Selecting 3D Scanning Equipment

If you plan to purchase 3D scanning equipment, you want to be sure of your choice. Consider the following factors as you reach a decision about what to buy:

1. Object characteristics - 3D scanning equipment can be used to collect measurement data for objects of almost all shapes and sizes. However, the type of equipment you select depends on the surface characteristics of the object, whether it has internal geometry, its size, and other factors.
   
   
2. Speed - How fast do you need results? Some devices provide faster results than others; however, speed can also impact quality and accuracy, so look at the big picture when you consider what equipment to buy.
   
   
3. Accuracy - This factor is extremely important in many industries. Do you need NIST traceability or an accuracy statement? Make sure that the equipment you buy can meet the accuracy requirements for your applications.
   
   
4. Cost - The cost of 3D scanning equipment varies, even within the same type and class of technology. Although equipment price is an important consideration, it should not be the only one. If the equipment you buy can't produce the results you need, your money will have been wasted.

If you're not sure what to buy, work with a reseller and service provider that has extensive expertise in 3D scanning. The people who use this equipment every day will be able to tell you which systems make the most sense for your needs.

Purchasing 3D scanning equipment is not your only option; you can also work with a qualified lab to outsource measurement services. This can be a more cost-effective solution if you don't often need 3D scanning or will be measuring multiple types of objects.

Whether you decide to buy equipment or outsource services, Q-PLUS Labs is here to help. We are a certified reseller for multiple manufacturers, and we provide 3D scanning, reverse engineering, and dimensional inspection services to all types of industries. Request a quote today to get started.

Do you want to embrace this modern method of measuring but don't know where to start?

When you work with subcontractors to fabricate parts or components, you must be sure that their quality standards are consistent both with your standards and with any regulatory requirements for the finished product. Ensuring supplier quality assurance is an essential step in your own QA process, but how can you confirm that all your subcontractors meet your specifications?

Three Steps to Ensure Supplier Quality Assurance

You can't constantly look over every supplier's shoulder, but if you follow three simple steps, you can establish and verify quality standards that will help ensure that you get what you want from your subcontractors:

1. Clear expectations - Communicate your expectations both in your engineering drawings and in discussions with your suppliers. They can't produce quality results if they don't know what you expect. After you have supplied engineering drawings, confirm that your supplier is satisfied with them and does not need any clarification.
   
   
2. Precise engineering drawings - Don't leave any room for interpretation in your engineering drawings. The more precise details you can provide, the more likely you are to get the results you desire. Remember that a good engineering drawing takes into account the design intent, the manufacturing process, and the inspection/verification process.
   
   
3. Certifications - When possible, look for suppliers that have ISO 9001 certification. When this is not possible - for example, in the case of small specialty suppliers that don't have the resources to achieve certification - consider a survey, audit, or other self-certification process.

Creating a supplier quality assurance protocol in advance is always more cost-effective than solving the inevitable problems that will arise if you don't follow these steps.

Q-PLUS Labs can help ensure supplier quality assurance at many steps in the process. We work with many small manufacturers to satisfy their customers' QA requirements. We can also provide third-party independent quality assurance and quality control inspections including first article inspection, in-process inspection, and process control. If you need assistance with any quality assurance issues, contact us today for a consultation.

Whether you decide to outsource reverse engineering services or purchase equipment so you can do it in-house, you must work with a qualified provider that you trust. The reasons may be obvious in the case of outsourcing, but selecting a good reseller when you decide to buy is just as important.

Whichever route you choose, make sure your vendor satisfies the following requirements:

Four Criteria for Outsourcing Reverse Engineering Services

For many reverse engineering applications, selecting a qualified provider is critical, especially if you must satisfy regulatory requirements. Look for the following factors when you evaluate providers:

1. Certification and accreditation - The current certification standard is ISO 9001, and the accreditation to look for is ISO 17025.
   
   
2. Expertise - Look for a long track record of success in multiple industries, particularly the one in which you operate.
   
   
3. Technology - Advances in reverse engineering technology are ongoing. Look for a provider that stays on the cutting edge and adopts new measurement and scanning technologies as they are developed.
4. Diversity - Successful reverse engineering is sometimes a combination of science and art. A reverse engineering provider that has experience across a range of industries and applications will be better able to solve problems and produce the best results.

Seven Criteria for Purchasing Reverse Engineering Equipment

If you have ongoing reverse engineering needs, purchasing equipment for in-house use might be more cost-effective. Although there are a number of places where you can purchase equipment, not all providers are created equally. Look for the following factors when selecting a vendor:

1. Collaboration - Most reverse engineering equipment requires an investment that you want to feel confident about making. Look for a provider that will help you select the best solution for your needs and not just sell you the device that will boost its bottom line.
   
   
2. Diversity - Working with a reseller that carries multiple manufacturers will give you more choices and help ensure that you evaluate all the available options.
   
   
3. Flexibility - If you are working with a limited budget, look for a provider that allows you to lease equipment or set up a payment plan.
   
   
4. Expertise - The companies that also use reverse engineering equipment are the most qualified to help you decide what to buy. A provider that uses the same devices every day will be better able to help you make an informed decision than a provider that only sells equipment.
   
   
5. Installation - Before you buy or lease the equipment, make sure your provider offers installation, calibration, and validation services so you can be confident that you have the proper setup.
   
   
6. Training - Look for a provider that offers a variety of training options, especially if your staff will need to learn how to use your new equipment.
   
   
7. Support - Sometimes problems arise. You don't want to be left on your own to troubleshoot or to set up maintenance schedules. Also, understanding your equipment warranty is important in order to ensure that you fulfill any requirements. Look for a provider that offers ongoing support so you can get the most from your investment.

Whether you decide to buy or outsource, Q-PLUS Labs can help. We meet all of the above criteria and more. We'll work with you to find the best solution for your reverse engineering needs. We'll even help you make the decision whether to buy or outsource. Request a quote today to get started.

What do you look for in a reverse engineering provider?

 

 

If you have decided that purchasing your own reverse engineering equipment is the most cost-effective solution for your project, the next step is determining what to buy. Countless types of equipment are available, with a range of features and from several manufacturers.

So how will you know what to buy? Follow these tips:

Nine Factors for Purchasing Reverse Engineering Equipment

1. Sensor type - The object's surface characteristics and other factors will determine what type of sensor will be best for your application. If you're not sure, work with a trained professional before you make an investment to ensure that the equipment you buy will produce the desired results.
   
   
2. Sizes of objects - Reverse engineering a car door handle requires different equipment than for a much larger object, such as an airplane propeller. When it comes to purchasing reverse engineering equipment, sometimes size does matter.
   
   
3. Shapes of objects - The shape of the objects you intend to measure will play a role in your purchasing decision. For example, you may need to add a bore probe if the object has cavities or holes.
   
   
4. Tolerance levels - Make sure you know the required tolerances in order to ensure that your equipment can achieve them.
   
   
5. Budget - When you buy equipment, the budget encompasses much more than just the sticker price. Consider other factors such as the costs to operate, calibrate, and maintain the equipment in the long run.
   
   
6. In-house skills - Make sure that your staffers have the skills to operate any new equipment you buy. If they do not, you may need to invest in training.
   
   
7. Maintenance requirements - Find out what regular maintenance is required before you buy so there are no surprises down the road.
   
   
8. In-house capacity - Determine whether the equipment you are purchasing will be able to meet your reverse engineering needs in a timely manner. 3-D scanning an object can take several hours; if you need fast turnaround time for multiple projects, consider purchasing multiple devices or partially outsourcing as needed.
   
   
9. Purchasing method - Look for a provider that gives you the option to buy or lease equipment, especially if you're uncertain how long you will need it.

If you're not sure what equipment to buy, work with a qualified provider that offers devices from multiple manufacturers.

Q-PLUS Labs is an authorized reseller for many different manufacturers. We offer the option to buy or lease, and we can often provide refurbished equipment to help you save money. We also use the equipment in our own labs, so we are uniquely qualified to help you make an informed decision. Contact us today with your questions or for assistance with buying reverse engineering equipment.

What type of reverse engineering equipment are you considering purchasing?

If you have decided that outsourcing reverse engineering services makes the most sense for your project or business, you still have some decisions to make. Not all reverse engineering applications are the same. You must decide what type of equipment to use and what kind of output you need, as well as consider a range of other factors.

This checklist is designed to help you get started.

7 Questions to Ask When Outsourcing Reverse Engineering

1. What is the objective of reverse engineering? Your provider will need to know your end goals in order to help you make the most cost-effective decisions.
   
   
2. What type of reverse engineering makes the most sense for your application? You can decide between design intent, verbatim (as-built), or a hybrid of the two. When reverse engineering for design intent, the measurements of the original object may be adjusted to correct for imperfections so that the final product will function in the desired way. The verbatim approach aims to create an exact replica of the original object, including imperfections, and the hybrid approach can be used in cases when the original object features multiple types of surfaces.
   
   
3. How should you process measurement data? When gathering measurements to reverse engineer an object, you can use a dimension-driven approach, shrink-wrap surfaces, or a combination of the two.
   
   
4. How accurate do you need to be? Depending on your objectives and the reasons for reverse engineering, your application might need a certain degree of measurement accuracy. For example, in the case of an object that must meet regulatory specifications, accuracy is extremely important. However, if you are replicating a statue for sale in a gift shop, some minor differences are acceptable. 
   
   
5. Does the original object need to remain intact? In some cases, in order to get the most accurate measurements, the original object will need to be disassembled or even destroyed. If this is not an option for your application, your provider must know that at the beginning of the process.
   
   
6. What type of equipment should you use? Many different types of measurement equipment can be used for reverse engineering. Your provider will consider the level of accuracy required, surface characteristics of the original object, and many other factors when deciding how best to take measurements.
   
   
7. Do you need to measure the object in a constrained state? For some applications, measuring the object while in a state that simulates how it's shape will conform in assembly makes more sense. You might also need to measure other objects or parts if you are reverse engineering an item that is part of an assembly.

Your provider can (and should) help you answer many of these questions, so don't be afraid to ask.

One of the greatest advantages of outsourcing reverse engineering services to providers such as Q-PLUS Labs is that we operate across multiple industries. This means that we offer a broad range of equipment types and the expertise to handle almost any reverse engineering application. Contact us today to learn more or to get started on your next reverse engineering project.

 

If you need reverse engineering for your business, you may come to a point when you must decide if you want to outsource to a qualified provider or purchase equipment to do the job in-house.

Both approaches come with advantages and disadvantages. Ask the following questions to help you make an informed decision:

• How frequently do you need to perform reverse engineering? If the answer is not that often or for a short-term project, you might consider outsourcing as a more cost-effective solution. On the other hand, if you foresee a consistent need for reverse engineering, buying or leasing equipment might be a better approach.
  
  
• How quickly do you need results? If the answer is yesterday, outsourcing is likely to be faster than purchasing new equipment and training staff to use it. If you think buying is a better solution, factor in the time needed to acquire equipment and train your staff.
  
  
• How much can you spend? Working backward from a set budget is a good way to evaluate your options. Remember to factor in more than just equipment costs. You might also need to train staff and pay for maintenance, so the up-front expenses do not necessarily reflect the total cost of ownership. On the other hand, if you will need reverse engineering services for the long run, owning your equipment could cost less over time.
  
  
• What types of objects do you need to reverse engineer? If you expect to scan multiple objects with different sizes and surface characteristics, you might actually need more than one piece of equipment to get the job done. Outsourcing to a provider that has multiple devices can save you time and money. However, if you know you'll be reverse engineering similar objects, doing it in-house could be more efficient.
  
  
• Does your staff know how to reverse engineer? Just because employees are skilled in one area does not mean that they will have the necessary knowledge and skills to use new equipment that they are not familiar with. If you do decide to buy, consider investing in training.
  
  
• Is NIST traceability important? If you require NIST traceability, ensuring that the personnel operating the equipment have the necessary skills becomes even more important. A qualified provider can ensure NIST traceability, or you can train staff so you can achieve it in-house.
  
  
• Can you handle tech support and maintenance in-house? Owning equipment means that you are responsible for calibrating, operating, and maintaining it. If you’re not prepared to do this for the life of the equipment, consider outsourcing. Some equipment resellers also provide ongoing training, support, and maintenance, so if you do buy, look for a provider that offers these services.

One approach that many businesses take is outsourcing before they decide to make an equipment purchase. This way, you can ensure that the equipment you are considering is adequate for the task at hand. You will also have time to hire skilled staff or train your existing employees to use the new equipment.

Whether you buy or outsource, Q-PLUS Labs is here to help. As a reseller of multiple types of equipment, we offer a large selection of manufacturers. Because we use this equipment in our own labs, we are uniquely qualified to help you make the best selection for your specific needs.

If you’re not yet ready to buy, we can perform the reverse engineering for you, either for a single project or on a long-term basis. Get in touch with a representative today to start exploring your reverse engineering options.

 

When we talk about reverse engineering and dimensional measurement, we often refer to manufactured parts, engineering tolerances, and other abstract concepts. Although we don't often encounter this particular type of project, this case study provides an excellent example of reverse engineering in action.

Mike M. came to Q-PLUS with an uncommon request and an even more unique story behind it. 

Butter Dish Beginnings

In 1979, Mike's grandparents hosted a family gathering. All was going well until the smoke alarm went off! After much searching and a hint of panic, the source of the smoke was discovered: A plastic butter dish had fallen onto the dishwasher’s heating element, melted, and triggered the smoke alarm. 

The unlucky cousin who had loaded the dishwasher looked in and asked, "Is it ruined?" One look at the clearly ruined butter dish sparked hilarity and prompted her grandfather to mount it on a plaque and present it to her. The butter dish became a family award that was presented annually to the person who had done the dumbest thing the year before.

Some of the most memorable awards were given to:

• The grandfather who tried to fix the bathroom plumbing without turning the water off first
• The brother-in-law who mistakenly wore one new shoe and one old shoe on a trip to Europe
• The niece who fell asleep on the New York City subway, missed her stop, and lost her companion in the process
• The uncle who, in a middle-of-the-night indigestion attack, reached for a bottle of liquid antacid and took a swig of white glue instead

For more than 25 years, the not-so-coveted award was passed around the family. Eventually, the original award-winner decided that she wanted this special keepsake permanently back in her possession. What was the rest of the family to do?

Barriers to Butter Dish Duplication

Mike decided to explore the option of replicating the cherished (and deformed) butter dish to carry on the family tradition. He went to the R&D department at the medical device company where he works and asked if they could possibly make a copy using the in-house 3-D printer.

The initial response was, "A butter dish? Sure, we can copy that." But after one look at this butter dish in all its melted glory, the R&D team members decided that it was beyond their capabilities. It was too complicated because the shape was so irregular. However, they did recommend a lab that they sometimes used for outsourcing this type of work.

Mike contacted the recommended lab and thought he had found a solution ... until he sent a picture of the butter dish. Foiled again!

Q-PLUS to the Rescue

Still on a mission to continue this unique family tradition, Mike turned to the trusty Internet. He found the Q-PLUS website, filled out the contact form, and got a return phone call in 15 minutes. Unlike the R&D team and the first lab Mike tried, we were not only up for the challenge, but we also were excited about it. What a great story!

Unlike many of our other projects in which clients send in objects for reverse engineering, this was a special case. Mike was concerned that a melted butter dish received in the mail would not get the respect it deserved and could possibly get lost (or tossed) after all these years. We scheduled time on a Saturday for him to bring the award in and have it scanned.

For the scanner, we used a high-end white light scanner: a Steinbichler Comet 5 4M. There are less powerful scanners we could have used for a project like this, but our team got caught up in the excitement and wanted to produce the best possible results. The white light scanner was used because we needed a massive amount of highly accurate data to capture the detail of the melted butter dish. This device was also selected because it provides relatively fast results and budget was a consideration.

This particular project is a perfect example of “as-built” reverse engineering. The goal was to create a replica of the original object, errors and all (and clearly, this butter dish was rife with errors!). On the other hand, if we were reverse engineering for design intent, we would have tried to produce a functional butter dish that matched its pre-melted state.

Butter Dish 2.0 Is Back in Action

Mike was able to take our digital scan and have a replica made using a 3-D printer. Butter Dish 2.0 lives on, and the family tradition remains uninterrupted.

In addition to achieving the desired goal, Mike was happy to learn more about the scanning and printing process. He thought that it was amazing that an object, especially one so complicated, could be replicated so exactly.

When asked about his experience with Q-PLUS, Mike said:

“Q-PLUS was very responsive. Within 15 minutes, I received a return call. Throughout the process, they were very engaged and had good follow-through every step of the way. I know my request was unusual, but they were very accommodating and flexible with scheduling so I could bring the butter dish to the lab myself.”

Now that the butter dish replication problem is solved, Mike's biggest worry is that he will be the next award-winner!

View the Butter Dish Scan

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In order to obtain an engineering degree, you must learn certain concepts and skills in school. However, developing an engineering career means your education continues on the job. One field not typically taught extensively in engineering school is metrology, but for any engineer entering the field of manufacturing, understanding metrology is essential. 

In the simplest terms, metrology is the science of measurement. In practical terms, when it comes to manufacturing, engineers have a vested interest in knowing the fundamentals of geometric dimensioning and tolerancing, commonly referred to as GD&T. Engineering drawings and 3D CAD models use GD&T to communicate engineering dimensions and tolerances to manufacturing and quality staff. If the engineer doesn't know how to effectively communicate in the language of GD&T, the finished product will likely not meet the desired outcome.

Why Understanding Metrology Is Important

The purpose of engineering design is to convey information in a way that makes it as easy as possible for the manufacturing team to create the desired parts and assemblies. A good engineering drawing will consider:

• The design intent
• The people and processes involved in manufacturing
• The inspection and verification process

The consequences of not understanding the fundamentals of GD&T can be dire:

• Disruption of manufacturing schedules
• Damaged reputations because of the inability to fulfill requirements
• Inability to meet budgets

Because metrology is so important in the manufacturing industry, there are several benefits for young engineers to learn it sooner rather than later:

1. Quality - Good engineering drawings result in parts that match the design intent.
   
   
2. Budget - Getting a drawing right the first time saves money.
   
   
3. Time - When dimensions and tolerances are stated clearly and thoroughly, manufacturers do not need to take the time to ask questions or get clarification.
   
   
4. Customer satisfaction - Producing the correct results in a timely manner keeps customers happy.

So how does a engineer learn more about GD&T if it's not commonly part of the standard curriculum? The American Society of Mechanical Engineers (ASME) offers the Y14.5 - 2009 Dimensioning and Tolerancing specification. This set of guidelines describes the language of GD&T and establishes uniform practices for communicating the requirements on engineering drawings. Additional resources include training programs and traveling seminars.

Q-PLUS Labs offers both training and consulting services to help ensure that your manufacturing process goes as smoothly as possible. Our training programs are designed for small groups across multiple disciplines so that engineers, manufacturing staff, and other key players can learn how to most effectively communicate in the language of GD&T. Contact us today to learn more about how we can help you.

Are you an engineer in the field of manufacturing? Tell us in the comments section how you learned about GD&T.

 

There are many ways to inspect an object. You can use high-tech machinery, precision hand tools, and even the human eye. Every inspection method comes with strengths and weaknesses, and each application will work better with some methods than with others. Understanding these strengths and weaknesses can help you decide which types of inspections work and do not work for your specific application.

Visual inspection is perhaps the original method, and it is still often the first line of defense in inspection and verification processes. The eye is a powerful inspection tool mainly because it is connected to a human brain that possesses information and skills that machines do not. However, the eye can be tricked, so knowing its limitations is important.

The Strengths of Visual Inspection

Almost all manufacturing applications should include visual inspection at some stage of the process for these primary reasons:

• Save money - If there is an obvious flaw that can be seen by the naked eye, there is no need to take the time and resources to continue the inspection process.
  
  
• The human element - Dimensional inspection evaluates just that: the dimensions. But what if the object produced is a mirror image of the intended result? This could be overlooked in an open setup or a non-model-based CMM inspection because the dimensions might exactly match the specifications. However, a visual inspection to compare the final product with the engineering drawings would quickly show the mistake.
  
  
• Evaluate workmanship - Certain types of dimensional inspection equipment measure the edges of an object but not the surfaces, or vice versa. Take the example of a cube. Your CMM might confirm that the surfaces of the cube are the correct dimensions, but it might not detect a large gash on one of the edges. Visually inspecting parts can help ensure that all of the specifications are met, not just the ones the equipment can see.

The Weaknesses of Visual Inspection

Although the human eye is a sophisticated tool, it can also be easily tricked. Consider some of these weaknesses associated with visual inspection:

• Unreliability - Browse through these optical illusions to get a sense of just how unreliable the human eye can be. This does not mean that visual inspections are always unreliable, but that they shouldn't be your only method of inspection.
  
  
• Imprecision - The human eye is not capable of making precise measurements, especially on a very small scale. Even when comparing two similar objects, the eye might not notice that one is slightly smaller or larger than the other. This concept also applies to characteristics such as surface roughness, size, and any other factor that needs to be measured.

Clearly, visual inspection comes with advantages and disadvantages but the value of it should never be quickly counted out. The best approach to effective dimensional inspection is one that includes multiple methods. Q-PLUS Labs is here to help you decide which dimensional inspection approach is right for your application. Contact us today to schedule a consultation.