How 3D Metrology Solutions helped BAE Systems produce detailed digital models

BAE Systems, a global defence, aerospace and security company, wanted to enhance their vehicle storage capabilities by accurately visualising and optimising storage positions for firearms within their tanks. Specifically, they required detailed digital models of a Glock handgun and a General-Purpose Machine Gun (GPMG), for which no existing CAD models were available.

This case study explores how 3D Metrology Solutions supported BAE Systems, through reverse engineering and 3D scanning. We’ve outlined the meticulous process we used to help create the required models, from the methodologies used to the challenges and outcomes.

Project objectives

These were the overall goals:

• Accurate 3D modelling: Create detailed, high fidelity digital models of the Glock and GPMG.

• Storage visualisation: Use these models to determine optimal storage configurations within the tanks.

• Non-contact 3D scanning: Ensure the firearms were not dismantled or damaged during the scanning process.
  
  

Project scope

The project involved the following:

• Equipment selection: Choosing appropriate metrology tools for high accuracy scanning.

• Initial scanning: Capturing the geometric details of the Glock and GPMG.

• Data processing: Converting raw scan data into usable 3D models using Polyworks software.

• Visualisation: Integrating models into CAD software to simulate storage configurations within the tanks.

• Validation: Ensuring models accurately represented the physical objects.
  
  

Methodology

1. Preparation and planning
   

Initial consultation:

• We conducted meetings with BAE Systems to understand specific requirements and constraints.

• Employing 3D solutions, we reviewed the physical dimensions and features of the Glock and GPMG.

• We developed a detailed project plan.

Equipment selection:

• We selected the Romer Arm for flexible, handheld scanning to capture intricate parts.

• We chose Polyworks software for data processing and modelling.

2. Initial scanning

Scanning setup:

• We prepared a controlled environment to ensure stable conditions during scanning.

• We set up the Romer Arm for high precision scanning.
  

Non-contact scanning process:

• Glock Pistol: Scanned the entire surface without dismantling the firearm, capturing every detail from multiple angles.

• GPMG: Employed a similar approach, ensuring all components including the barrel, receiver and stock were accurately scanned.

3. Data Processing

Raw data conversion:

• Point Cloud generation: Collected data from the scans and converted it into dense point clouds representing the surface geometry.

• Mesh creation: Processed point clouds into mesh models.
  

CAD model development:

• We imported mesh models into Polyworks for further refinement.

• We ensured that the models were true to the physical dimensions and features of the firearms.

4. Visualisation and analysis

Storage configuration simulation:

• We imported CAD models of the Glock and GPMG into the existing CAD model.

• We simulated various storage configurations to identify the most efficient and secure arrangements.

• We analysed the ease of access and ergonomic factors for soldiers retrieving the firearms.
  

Model validation

• We compared CAD models with original firearms to verify accuracy.

• We conducted dimensional checks and visual inspections to ensure fidelity.

5. Documentation

Comprehensive reporting:

• We generated detailed technical reports outlining the scanning and modelling process.

• We documented storage configuration simulations and analysis results.

• We provided BAE Systems with complete digital archives of all models and reports.

Challenges and solutions

1. Complex geometries

Challenge: Scanning the intricate details and complex geometries of the firearms, particularly areas with tight spaces or irregular shapes.

Solution: We used the Romer Arms flexibility and Polyworks’ advanced processing capabilities to perform multiple scanning passes at different angles. This ensured comprehensive coverage and detailed capture of complex geometries.

2. Environmental factors

Challenge: Ensuring consistent data quality in varying environmental conditions, such as lighting changes and potential vibrations during scanning.

Solution: We conducted scans in a controlled environment, using calibration routines before each scanning session to account for any changes.

3. Handling reflective surfaces

Challenge: Scanning reflective surfaces on the firearms, which can cause issues with scanning due to reflections and noise in the scans.

Solution: We applied a temporary Scanning spray (AESUB) to reflective surfaces to reduce reflections and enhance scan accuracy. Additionally, we adjusted scanner settings to optimise performance for reflective materials.

Project outcomes

These were the project outcomes: 

• High-fidelity 3D models: We created accurate and detailed digital models of the Glock and GPMG.

• Optimal storage configurations: We identified efficient storage solutions within the tanks, enhancing accessibility and ergonomics.

Conclusion

We helped BAE Systems to achieve all primary objectives, making this project an overall success. This was due to the extensive knowledge of the 3D Metrology Solutions team in reverse engineering and 3D scanning.

The use of the Romer Arm for scanning, and Polyworks for data processing, ensured the creation of high-fidelity digital models and optimal storage configurations. This project highlights the importance of precision and non-contact techniques in reverse engineering, providing valuable insights and tools for future applications.