3D Scanning and Reverse-Engineering of an Impeller

Impellers are a key part of many industrial processes that require precise flow dynamics and mechanical durability. Borealis Polymere needed a solution to manufacture an old impeller without the original CAD models. MLT Machine & Laser Technology Oy performed precision measurement of the impeller using 3D scanning, and 3D Formtech Oy manufactured the new component using 3D printing.

The importance of 3D scanning in impeller modeling

The importance of 3D scanning in impeller modeling we used Creaform’s Handyscan Black+ Elite 3D scanner to capture the complete geometry of the impeller. Compared to traditional measurement methods, 3D scanning enables significantly more accurate and comprehensive data collection, especially for complex geometries such as impellers.

What we get from 3D-scanning the impeller:

• Micrometer-level accuracy of the entire component’s surface contours.
• Fast and non-contact measurement without mechanical stress on the part.
• Comprehensive point cloud data that served as the basis for CAD modeling.

Reverse Engineering – from old to new

Once the scan data had been collected, MLT’s experts performed reverse engineering using CAD software. The point cloud data was converted into a parametric 3D model that could be modified and optimized for manufacturing.

During reverse engineering:

• Worn and inaccurate areas in the original impeller were corrected.
• Original structure and shape were retained
• Machining allowances were added to the model for machined surfaces

Process

3D printing – fast and cost-effective manufacturing

After the modeling was completed, 3D Formtech Oy was responsible for manufacturing the impeller using the 3D printing method.

Benefits of 3D printing:

• The ability to manufacture complex geometries without traditional mold costs.
• Shorter lead time compared to machined methods.
• High dimensional accuracy and repeatability.

End result and benefits

As the end result of the project, Borealis received a perfectly reverse-engineered and 3D printed impeller that matched the original part in both design and function. The combination of 3D scanning, reverse-engineering and printing provided:

• A fast solution without original design files.
• An accurately replicated and optimized component.
• A cost-effective and innovative manufacturing method.
• Delivery time was reduced from 3 months to 4 weeks.

MLT Machine & Laser Technology Oy and 3D Formtech Oy offer expert solutions for demanding industrial measurement and manufacturing needs. Contact us if you need similar services for your project!