Three-dimensional image reconstructions of complex objects by an abrasive computed tomography apparatus

The process of capturing the shapes of objects through surface data sampling and generating a 3D CAD model is termed reverse engineering (RE) because the process is the reverse of the normal design and manufacturing sequence. The digitisation process can be achieved through spatial measurements taken by a coordinate measuring machine (CMM). The way of capturing data in a CMM can be divided into contact or non-contact methods. Diode-lasers or CCD cameras are commonly applied in non-contact measuring, while touch probes are applied in contact measuring. There are limitations in obtaining data for complex objects (for under-cut or inner structures) by means of the two abovementioned methods. Therefore, we have designed and assembled a novel device, called an abrasive computed tomography (ACT) apparatus, to overcome the abovementioned limitations. The ACT apparatus uses an abrasive method to remove the inlaid object layer by layer and to capture the cross-sectional image of each layer with a CCD camera. A numerical scheme is applied to obtain the Bezier curve of the boundary in each layer. The combination of all cross-sectional boundaries is used to reconstruct the 3D CAD model of the object. The 3D CAD model can then be transmitted to generate the tool paths in a CNC machine or produce rapid prototyping in a RP machine.