TABLE OF CONTENTS 

INTRODUCTION .......................................................................................................................... 1

OBJECTIVE ................................................................................................................................... 1

DELIVERABLES ........................................................................................................................... 2

APPROACH ................................................................................................................................... 2

SETUP ............................................................................................................................................ 2

Equipment List ............................................................................................................................ 2

Configuration of the Tractor for Scanning .................................................................................. 4

Configuration of the Trailer for Scanning .................................................................................. 6

Configuration of the iGPS System for Scanning ........................................................................ 8

SCANNING AND MODELING ASSUMPTIONS ..................................................................... 11

Tractor Scanning and Modeling Assumptions .......................................................................... 11

Trailer Scanning and Modeling Assumptions........................................................................... 14

FINAL MODELS ......................................................................................................................... 15

PROJECT MANAGEMENT NOTES .......................................................................................... 16
INTRODUCTION 

In support of the aerodynamic analysis effort for EPA’s SmartWay Transportation Partnership 

program, Southwest Research Institute® (SwRI®) and its subcontractor, Nikon Metrology, 

provided 3D laser scanning and modeling services, capturing the exterior geometry of a highroof, aero sleeper cab Class 8 tractor and its 53-ft. trailer (Figure 1). This document describes the 

equipment and methods used, modeling techniques, and illustrations that capture the 

chronological sequence of digitization activities. Finally, some discussion is provided regarding 

project management aspects of the truck digitization, including information about productivity 

and suggestions for future digitization efforts of this nature. 

Figure 1. High-roof aero sleeper cab Class 8 tractor and its 53 ft. trailer prior to scanning. 

OBJECTIVE 

The objective was to digitize a Class 8 truck (tractor and trailer) for the dual purpose of 

computational fluid dynamic analysis and to enable fabrication of a rapid prototype scale model 

for wind tunnel testing (closed-grill model). The output file format was to be STL, which is 

compatible with common computational fluid dynamics software including Star CCM, 

PowerFlow, and FLUENT, and is also compatible with additive rapid prototyping machines. 

1 
DELIVERABLES 

The contractual deliverables for the truck digitization effort included the following: 

• 3D models in STL format for the 

o Trailer including aero kit 

o Trailer excluding aero kit 

o Tractor 

• Technical report (this document) 

SwRI also provided (not contractual): 

• A photo archive of the whole process 

• Laser scanner point cloud data 

• 3D models in IGES and Sldprt (SolidWorks) formats 

APPROACH 

To avoid error stack-up due to instrument leap-frogging, the truck was scanned using a twoinstrument approach. An iGPS (infrared laser positioning) system was first used to probe 

coordinate frame nests, acquiring their X,Y,Z positions in a single encompassing coordinate 

frame. An articulated arm with laser scanner was then used to scan the exterior of one side of the 

truck, including the underbody. The opposite side of the truck was modeled as a mirrored copy 

of the scanned side, except where asymmetries existed (e.g., tractor exhaust manifold). The 

nominal resolution of the point cloud was 1.5 mm. Laser scan data patches were stitched together 

using the coordinate frame nests whose positions were determined with the iGPS system. In this 

way, the maximum incurred error did not exceed the combined error of the iGPS and CMM laser 

scanner arm, plus any errors related to small variations in the temperature of the building and 

mounting flexure. Local error when matching iGPS and scanner data was observed to be better 

than 1 mm. Global error, which could be additionally influenced by temperature variation, is 

estimated to have been better than 2 mm. For this size vehicle, errors of this scale were assumed 

to have negligible influence on the outcome of aerodynamic analysis. 

SETUP 

The truck was moved to SwRI building 9800, which is a large temperature-controlled building 

with approximately 20 ft. of clearance to the roof support structure. The tractor and trailer were 

scanned sequentially as separate entities to improve physical access to the surface of both. The 

sub-sections that follow (pages 3 - 8) describe the equipment used, and the particular setup for 

the tractor and trailer. The setup of the iGPS equipment is also described. 

Equipment List 

The following tables provide the tractor and trailer specs. 

 

2 
Table 1. Tractor Specifications 

Manufacturer MY International 

Model ProStar Premiun Sleeper Cab 

Type Class 8 Sleeper Cab 

VIN 2HSCUAPR6AC168660 

Tractor ID 1660-HD-01 

Table 2.Trailer Specifications 

Manufacturer Great Dane 

Owner ID 123458 

Model SSL-1313-02053 

VIN Number 1GRAA06219J628785 

Manufacture Date December 2007 

Model Year 2008 

GVWR 68,000 Lbs. 

Rear Axle Tires Bridgestone R195 

Tire Size 295 / 75 /22.5 

Rims/Make Accuride DOT T 

The following hardware tools were used to acquire the surface data (refer to the Appendices for 

more information about the metrology tools used): 

• Nikon Metrology (formerly Metris) iGPS G5 system, including the following subcomponents: 

o 8 laser transmitters, each on Brunson instrument tripods 

o 2-meter Invar calibration bar 

o Hand-held vector bar w/ 5mm ball tip and wireless PCE 

o Dell laptop workstation 

• Nikon Metrology MCA 2 meter scanning arm w/ MDD 200mm laser scanner 

• Set of synchronized portable 220V electric wheel lifts 

• Jack stands 

• Battery powered ~18 ft. scissor lift 

• Battery powered ~12 ft. vertical man lift 

• Movable ~15 ft. stair case 

• 3 Large I-beams for mounting the scanning arm under the truck 

• Step ladder 

• Safety equipment including harnesses, hard hats, gloves, and safety glasses. 

 

3 
The following software programs were used for acquiring and then post-processing the scan data 

to generate STL models: 

• Nikon Metrology Surveyor 1.4 software to bundle, configure, and run the iGPS 

• New River Kinematics Spatial Analyzer software to collect, visualize, and analyze nest 

data points and interface with the iGPS. 

• Nikon Focus Handheld to calibrate the laser scanner, collect the data, and decimate the 

data down to useable resolution. 

• SolidWorks 2011 to generate reverse-engineered model of the trailer and to generate the 

combined model. 

• Polyworks to generate reverse-engineered model of the tractor 

Configuration of the Tractor for Scanning 

The tractor was prepared for scanning first. Four portable electric wheel lifts were used to lift the 

tractor ~31⁄2 ft. off the ground. The lifts were placed under the front wheels and under the forward 

rear axle based on the fact that weight would be more evenly distributed. Once the tractor was 

suspended, jack stands were placed at hard points along the center frame rails (Figures 2 and 3). 

I-beams were secured to the floor underneath the tractor using hot glue to provide a mounting 

flange for the scanning arm (Figure 3). Standoffs were also glued to the I-beams every couple of 

feet to provide rigid nests for the scanning arm to locate itself with reference to the iGPS 

absolute coordinate frame. A #6 threadless aluminum standoff makes a highly repeatable 5 mm 

probe tip nest for about 1/100 of the price of nests sold for that purpose. 

Figure 4 illustrates many of the nuances of scanning a Class 8 truck. Because the laser scanner 

has difficulty with reflective (e.g. chrome) or transparent surfaces, developer spray was used to 

coat these surfaces, making them frosty white. The laser scanning arm cannot be mounted to the 

same apparatus that supporting its human operator, because the shifting weight of the operator 

can introduce large errors in scanner’s base position. Therefore, the scanning arm was frequently 

mounted to an I-beam clamped to a two-story scaffolding (far right side of the image). Also, the 

front wheel was removed at the very end of the scanning job, so that the wheel well could be 

scanned. The final model of the truck used geometry from 23 scan data point clouds. 

 

4 
Figure 2. The tractor was scanned in a temperature controlled high bay. Two 

of the eight iGPS laser transmitters are visible on the white tripods. 

The yellow scale bar is on the black tripod in the center of the image.

Figure 3. The tractor was suspended off the ground so that the underside could be scanned.

 

5 
Figure 4. The front wheel of the tractor was removed to provide laser scanning access.

Configuration of the Trailer for Scanning 

The setup for the trailer was much simpler than for the tractor. The trailer was scanned separately 

from the tractor, sitting on its built-in jack stand (Figure 5). Due to its inherent ground clearance, 

it could be scanned without need to jack it up off the ground (Figure 6). This also simplified 

mounting for the scanning arm. A large portion of the trailer’s broad side and top surface did not 

need to be scanned due to the fact that they were featureless (large flat planes), so the scanning 

arm was moved along the ground, capturing the features of the lower edge, aero kit, and 

underside (Figure 7). The final model of the trailer used geometry from 13 scanned point clouds. 

 

6 
Figure 5. The trailer was scanned from front to back, separated from the tractor. The scanning arm was 

mounted to a tall Brunson tripod (center) to access the high surfaces of the trailer.

Figure 6. The inherent ground clearance of the trailer enabled scanning without need for jack stands.

 

7 
Figure 7. Since the variable geometry of the trailer was mostly found 

along the lower edges and underside, the scanner was able 

to collect needed geometry for the broad side from a short tripod.

Configuration of the iGPS System for Scanning 

The iGPS system was set up on one side of the tractor/trailer in an arc configuration to ensure 

signal coverage over the entire side. The iGPS Vector Probe was used to measure feature touchpoints and coordinate frame nests (Figure 8). The probe accuracy filter was set to 0.015 inches. 

This meant that the operator had to hold the probe very still in order to acquire a measurement. 

The system does not collect points if the calculated accuracy is worse than the filter limit. Each 

nest was tagged with a number to uniquely identify it. Once the nest positions were acquired 

with the iGPS system through the Spatial Analyzer software interface (Figures 9-12), the nest 

data was exported to a spreadsheet then laser scanning began. For each base position of the 

scanning arm, five or six nests were first measured to establish the coordinate frame of the arm. 

In the Focus Handheld software, which serves as the user interface for the arm, each nest was 

labeled with its unique identifier number. In post processing, the nest coordinates were assigned 

in the Focus Handheld software and a least squares fit was used to transform the point cloud data 

from the coordinate frame of the scanner to the global coordinate frame of the iGPS. The scanner 

was used to capture the geometry of all hidden (non-line-of-sight) areas like the underside of the 

vehicle. 

 

8 
Figure 8. The author used the iGPS system to acquire nest locations.

Figure 9. Profile view of the tractor nest point data. The silhouette of the tractor is 

apparent from the points along the top of the image. The points along the bottom 

are ground reference points used to localize the scanner when it was beneath the tractor.

 

9 
Figure 10. Top view of the tractor iGPS constellation and nest data points. Here the intent is to show the 

relatively large transmitter constellation, shown as small black dots with serial numbers around the 

perimeter of the image, needed to see all of the reference nests on the tractor. It is not readily apparent, but 

the front of the tractor is at left, and the rear of the tractor is at right.

100 ft.

41 ft. 

tractor nest points 

iGPS transmitters 

Figure 11. Rear isometric view of the trailer nest points. The pink points (left) are at the 

back end of the trailer. The green points are along the lower edge and 

skirt, and the blue points (right) are on the front face of the trailer.

 

10 
Figure 12. Top view of the trailer iGPS constellation and nest positions. Here, the small 

black dots at the periphery are the locations of the iGPS transmitters (8 total), 

the pink points (left) are from the rear face of the trailer, the green points (center) 

are from the right side face, and the blue points (right) are from the front face of the trailer.

42 ft. 

trailer nest points 

iGPS transmitters 

113 ft.

SCANNING AND MODELING ASSUMPTIONS 

Efficient reverse engineering requires a methodology to identify important design features and to 

discard superfluous design features. In the case of digitization for an aerodynamic study, the 

decision to keep or discard features cannot be simplified to a simple rule based only on size or 

cross sectional area. (We had started with the goal of capturing everything larger than 3 mm 

based on CFD literature). There are many considerations including the accessibility of the feature 

to line-of-sight, cost of modeling irregular/asymmetrical curved surfaces, and the need to close 

the model to make it a “water tight” solid. The subsections that follow describe how SwRI and 

its subcontractors chose which features to scan and model for the tractor and trailer. 

Tractor Scanning and Modeling Assumptions 

The following list summarizes the assumptions. To illustrate these considerations, Figures 13-16 

are provided. 

• Half of the tractor was scanned, the other half was generated by mirror-copying the 

model in post processing. Asymmetric features that were preserved in the model include: 

o Exhaust system manifold and stack. 

o Pneumatic air tanks (underside) 

o Transaxles 

o Engine oil pan 

• The model is a closed-grill model, which does not allow for airflow through the radiator 

and over the engine. The effort to reverse engineer the engine and under-hood geometry 

would double or triple the cost of this overall project. 

11 
• To close the underside of the engine compartment, a plane was inserted, approximately 

co-planar with the top of the main beams beneath the tractor. Only items below this plan 

were modeled. 

• Items that were obviously symmetric were not scanned in their entirety. For instance, the 

tires were assumed to be axisymmetric and only a patch was scanned. 

• The ride height of the front and rear axles was adjusted in the model to account for 

suspension loading/unloading while the tractor was on jack stands. 

• Cowling sheet metal was modeled as a zero-thickness surface. 

• Small gaps between body sheet metal were bridged to close the surface. 

• The interior hollow of the roof dome was assumed to follow the exterior contour, except 

where scan data was accessible. 

• Pneumatic hoses and electrical harnesses were ignored due to their small size and high 

complexity. 

• Mud flaps were modeled as flat. 

• Most fasteners were not modeled. 

• The steering gear for the front wheels was ignored. 

 

12 
Figure 13. Front view of the scan data overlaid on the final model. From this perspective, 

nearly every exterior surface feature from the scan data has a modeled counterpart.

Figure 14. Top rear isometric view of the scan data (grey) overlaid on the final 

tractor model (red). Note that the rear wheel data doesn’t overlay perfectly 

because the suspension preload had to be compensated in post processing.

13 
Figure 15. Bottom view of the scan data (grey) overlaid on the final tractor model (red). 

Trailer Scanning and Modeling Assumptions 

The following list summarizes the assumptions for scanning and modeling the trailer: 

• Half of the trailer was scanned, the other half was generated by mirror-copying the model 

in post processing. Asymmetric features that were preserved in the model include: 

o Rear ladder 

o Pneumatic tank for the air brakes (underside) 

o Hazard diamonds 

• The trailer model was provided in two variants: one that includes the as-built aero kit and 

one for which the aero kit had been digitally subtracted. 

• The main body of the trailer was modeled with flat sides that meet at right angles. The 

physical trailer sides bow or curve slightly in a manner that is unique to that trailer. 

• Certain areas were not captured entirely in the scanning process because symmetry or 

patterning was assumed. These areas include: 

o The driver’s side of the trailer (mirrored from the passenger’s side, which was 

scanned) 

o The hazard diamonds on the flanks of the trailer (assumed planar) 

o The band feature around the lower edge of the trailer (assumed constant crosssection) 

o The rivets and panel structures (patterned array) 

o The tire treads (simplified pattern used) 

o The rib structures on the underside of the trailer (patterned from single scanned 

rib) 

• A few areas of the trailer could not be scanned due to access limitations and are therefore 

less accurate. The features in these areas were extrapolated from existing scan data or 

modeled from hand measurements and observations. The areas of reduced accuracy 

include: 

o The undercarriage features between the wheels (some hand measurements were 

taken to augment scan patches) 

o The crown feature around the upper edge of the trailer (hand-measured and 

assumed to be constant cross-section) 

14 
FINAL MODELS 

Figures 16-18 show various perspectives of the completed model. 

Figure 16. Front isometric perspective of the completed model. Here the attention to detail in 

the tractor body and cowling is evident from the number of surface parting lines.

Figure 17. Rear top isometric view of the completed model. The model of the 

trailer relied heavily on assumptions of symmetric and repeated patterns.

 

15 
Figure 18. Front bottom isometric view of the completed model. This 

view highlights the detail of the underside of the trailer model. 

PROJECT MANAGEMENT NOTES 

One of the goals of the truck digitization project was to evaluate the feasibility and cost 

effectiveness of using the iGPS system as an absolute coordinate frame, enabling repositioning 

of the arm scanner without error stack-up, to cover the whole surface of the truck including the 

underside. From a technical perspective, the iGPS worked extremely well, knitting together scan 

data patches with an accuracy that exceeded the resolution of the decimated scan data (0.38 mm 

vs. 1.5 mm). From a cost perspective, the efficiency of the iGPS depends on the throughput of 

the particular scanning job (note that no iGPS equipment charges were assessed to the project, as 

it was used on a trial basis). Two other alternatives, a laser tracker or laser radar, could also 

provide similar functionality. The laser tracker would be much less expensive to own/operate, 

but would require multiple setups to gather the equivalent data. Laser radar could also have been 

used. Like the laser tracker, it is only a single piece of equipment (though similar in price to 

iGPS). The advantage of the laser radar is that it could capture point clouds and nest locations 

both. The scanning arm would still be needed if the laser radar was used, due to accessibility 

restrictions under the truck and inside the rear fairing. In answer to the bottom line question of 

the cost efficiency of the iGPS, it costs more than the laser tracker and it takes longer to setup 

than either of the alternatives. If a high through-put of scanning jobs was expected and setup 

only had to be done once, the iGPS would be cost effective. For infrequent large scale laser 

scanning jobs, the laser tracker is probably the most cost effective solution. 

16 
17 

Another project management interest is the cost comparison of digital aerodynamic drag 

calculation with empirical testing as it relates to compliance with future EPA fuel economy 

regulations. SwRI was not involved with the CDF analysis and cannot address the cost of that 

portion, but we can help to quantify the labor involved in digitization of a truck. Table 3 

documents the labor involved in scanning and modeling the tractor and trailer for this project. 

Note that report writing hours are excluded and subcontractor hours are estimated. Also note that 

the modeling labor would be at least twice as high if the engine/under-hood was reverse 

engineered to a similar degree of detail as the rest of the truck. Some cost savings could be 

realized if multiple trucks were scanned at once, but these savings would mostly be in the area of 

setup and breakdown labor, which were not dominant in the total cost. 

Table 3. Truck Digitization Labor Hours 

Description Est. Engineering Hours Est. Technician Hours 

Setup and Scanning 148 175 

Reverse Engineering/Modeling 203 0 

Total 351 175 
Appendix A: iGPS Product Data Sheets
niKOn MeTrOlOGy i VISION BEYOND PRECISION

Turn your shopfloor into 

a metrology enabled workspace

iSpace

Large volume metrology, tracking and positioning
iSpace drives Metrology assisted Production 

Scalable systems for large volume metroloy

iSpace systems can be scaled from small work cells to facility-wide installations by just adding more 

transmitters. The measurement volume is configured to the size of the application, resulting in 360° part 

coverage.

uniform accuracy for industrial large scale application

The typical accuracy of an iSpace system is 200μm. Where traditional metrology equipment accuracy decreases 

with distance and as a result of leapfrogging-related measurement errors, iSpace accuracy is uniform across 

the entire measurement volume, regardless of the size of the metrology enabled area.

inherent robustness

Unlike traditional laser-based metrology tools, iSpace offers 360° part coverage without line-of-sight issues 

thanks to transmitter redundancy. Continuous health monitoring including on-line compensation in case of 

transmitter displacement and drift, guarantees optimum system performance without user intervention. 

Easy to deploy and straightforward to use

Installing iSpace on the shop floor is easy and straightforward: just set up the transmitters on their portable tripods 

and calibrate the system by walking around in the measurement volume while holding a calibrated scale bar. As 

such, shopfloor measurement eliminates the need to transport large heavy parts to/from the measurement room.

Multi-user for concurrent applications

iSpace has the unique ability to serve multiple users simultaneously without performance loss. Once a work cell 

is iSpace-enabled, additional users and new applications can be added with minimum additional investment. 

Next to supporting a range of handheld metrology devices, iSpace positions tools or tracks multiple objects 

simultaneously, such as automated guided vehicles (AGVs) in a manufacturing environment. 

open solution that grows along with your measurement needs

As a modular and scalable solution, iSpace offers a broad application reach. Using off-the-shelf iSpace 

components, tailor-made tooling and the software development kit (SDK), all elements are present to build a 

custom solution that perfectly meets your needs.

aircraft fuselage inspection

•	Measure individual points on a fuselage using iMCA

•	iMCA allows for easy measurement of hidden points in the workspace 

Full car body inspection

•	Operators use iProbe to measure multiple car bodies without leap-frogging

•	Ideal for concurrent measurement of jigs/tooling

Measurement of features on large turbine casting

•	iProbe is used to measure surface features across the entire casting

•	 Full freedom measurement through wireless connection between PDA and portable client

Metrology applications

ideally, large parts or components are verified on the shop floor where they are produced. Measuring large heavy parts using 

traditional metrology tools may require transportation overhead to bring the parts to the measurement equipment. iSpace overcomes 

these challenges by converting your workspace into a metrology enabled facility where users can easily measure multiple parts. 
Handheld iProbe 

(6DOF)

Carbon scale bar iMCA

Metrology grade

transmitter

Metrology 

server

Expandable measurement volume... 

tailored configurations for each application

The iSpace portfolio consists of 3 standard setups, with 4, 6 or 8 transmitters. More transmitters create a larger measurement volume and 

further improve line of sight. The 4-series iSpace setup is easy to deploy, providing a smaller and unobstructed measurement volume. The 

6-series setup is typically used where left/right measurements are taken on a vehicle body, for example, while the 8-series preserves the best 

line of sight in a measurement volume with a footprint up to 1.200m2.

Each iSpace setup is available in different configurations: the x-series configuration is a portable lightweight system that is easy to set up. The

s-series are delivered with base stations that provide reference detectors for continuous health monitoring. 

The top-line i-series inherently provide highest accuracy and system robustness. They utilize fixed iSpace monuments to capture position and 

scale reference points throughout the workspace. After having determined the positions of the reference points during system setup using an 

external measurement device, iSpace continuously monitors these monuments to be able to maintain transmitter positions at highest accuracy.

dynamic tracking of ship models in towing tank applications

•	 Ship models are equipped with iSpace receivers

•	iSpace dynamic measuring to monitor real-time ship behavior

tracking and monitoring of industrial robots

•	 Sensors are embedded into robot and fixtures

•	 Single setup to monitor robots on a factory-wide scale

aligning and joining large subassemblies

•	 Fuselage sections, wings and body components are equipped with iSpace sensors to track their position

•	Monitoring of drilling and riveting robotic machining systems

iSpace offers dynamic tracking in support of precision assembly of large parts and continuous monitoring of tools 

and objects. As such, closed-loop iSpace measurements are directly integrated into the production and assembly 

stages, realizing a first-time-right Metrology Assisted Production process.

transmitter assembly with intgrated detector units

tracking applications 
... with countless applications

iProbe - lightweight 6doF metrology probe

The iProbe is a wireless handheld measurement device that provides exchangeable and 

inclinable 6DOF measurements within an iSpace or iGPS enabled workspace. Equipped 

with a stylus probe tip, the iProbe allows for accurate large volume inspection in the 

most flexible way. The iProbe can also be configured as a 6DOF localizer for 3rd party 

instruments. Accuracy is dependent on the iSpace setup, but is equal throughout the 

complete measurement volume. The system’s ergonomic design and wireless operation 

make iProbe suitable for long duration measurement.

iMCa – iSpace enabled articulated arm

The moveable iMCA tripod stand is designed to support a metrology grade MCA 

articulated measuring arm to operate anywhere within the iSpace enabled workspace. 

The iSpace determined position and orientation of the iMCA stand is combined with 

the coordinate information received from the MCA arm in order to measure a single 

point within the iSpace coordinate system. This ‘extends’ the working volume of 

the articulated arm and provides a large, continuous working cell without having to 

‘leapfrog’ measurements.

dynamic tracing kit

The Dynamic Tracking Kit (DTK) is an add-on to any iSpace system to support dynamic 

referencing and 6DOF part tracking. The DTK can be semi-permanently fixed to a part 

or jig and used for 6DOF tracking or dynamic referencing within an iSpace volume. 

The DTK can be configured to track a part’s local coordinate system by following a 

straightforward alignment procedure. 

Standalone or metrology server based

In a single application, data processing and system monitoring is handled by a portable, 

combined client/server workstation that runs the Surveyor control software and a (3rd party) 

application. In case of concurrent applications, the data streams and system monitoring are 

controlled by a metrology server that manages the connectivity between the measurement 

systems and multiple portable client applications.

Positioning of subassemblies to align for final ship assembly

•	Robust operation guaranteed for outdoor application

•	Components are equipped with iSpace receivers to support computer-guided assembly

applying marker positions for final machining purposes

•	iProbe is equipped with a miniature drill to mark positions

•	Operator is guided to correct position to create a mark

Coating thickness measurement in aerospace applications

•	iProbe is equipped with a coating thickness tool

•	Exact position recording of coating measurement

Acquiring real-time positioning information is essential in a wide range of large volume applications. iSpace can 

determine the exact position of large objects or parts, but can also measure the exact location of tools to suit 3rd

party applications, such as coating thickness measurement, drill marking, robot-guided painting, etc. 

Positioning applications
Full freedom operation in large volumes

iGPS technology provides the building blocks for the iSpace systems

iGPS is a scalable measurement concept that converts a workspace into a metrology enabled work 

volume. The operation of an iGPS system is comparable to a global positioning system (GPS) in a car, 

but it is designed for industrial applications on a facility-wide scale. GPS satellites are replaced by 

infrared iGPS laser transmitters that activate a measurement field as large as an entire room or facility. 

iGPS features accuracies that are roughly a hundred thousand times higher than consumer GPS systems. 

Tools, parts, probes and equipment, such as AGVs, can be equipped with iGPS receivers that are tracked 

by the transmitters. As such, positions can be measured or dynamically tracked with a high degree 

of confidence in order to provide accurate metrology data or to facilitate tracking and positioning 

applications.

To obtain accurate positioning, receivers need line of sight from minimum 2 transmitter fields. Adding 

more transmitters enlarges the measurement area, improves robustness by guaranteeing line of sight, 

and further increases measurement accuracy. iGPS is a flexible metrology solution that offers full 

freedom operation for indoor and outdoor use. The iSpace systems are standardized configurations built 

with iGPS components focusing on ease of installation and use.

iSpace delivers significant value to the customer, right from the start!
iSpace setups, configurations, tools and options

4 series 6 series 8 series

Transmitter count 4 6 8

Available configurations x, s x, s, i x, s, i

Typical measurement volume footprint from 10x10m up to 40x40m

Typical use case Smaller volume / Unobstructed 

line of sight / Lower accuracy

General purpose / Standard 

system size / Moderate line of 

sight obstructions

Larger volumes / Obstructed 

line of sight / Maximum 

accuracy

x s i

Hardware configuration Free network of transmitters Transmitters plus base stations Transmitters plus monuments

Calibration method Traceable scale-bar Traceable scale-bar Traceable reference network

Accuracy1,2 <250 μm over 3x scale-bar length3 <250 μm over 3x scale-bar length <200 μm uniformly over 

monument volume

Typical use case Portable/Deployable setup

Short term measurement and tracking

Engineering or R&D focused

Less health monitoring

Semi-portable or semi-fixed installations

Longer term measurement and tracking

Production focused

High level of health monitoring

Fixed installation

Always-on production system

Maximum system robustness 

accuracy and reliability

1 For optimum performance, it is recommended to keep the distance between sensors and transmitters between 3 and 35m and guarantee individual sensors to be within line of 

sight of at least 4 transmitters.

2 System performance testing according to B89 and ISO10360 in conjunction with an independent accredited measurement standards lab. iSpace is a network based metrology 

system that does not follow traditional uncertainty models. Coordinate uncertainties are interdependent, do not scale with range and are repeatable within the volume.

3 Requires stable transmitter positions and environmental conditions

Tools and options Available series Description

Metrology server 6, 8 Allows multiple independent clients to be used in the same iSpace network leveraging scalability

Dynamic Tracking Kit 4, 6, 8 Kit of 4 vector bar sensors allowing 6DOF tracking of an object in the iSpace volume

Handheld vector bar (5DOF) 4, 6, 8 2 sensor vector tool providing handheld inspection capability

iProbe (6DOF) 4, 6, 8 4 sensor 6 DOF tool providing handheld inspection capability with customizable probe tips

iMCA 6, 8 Support base for MC4 articulated arm that utilizes the iSpace system for automatic alignment

Related products

•	Hardware: iGPS / Laser Radar / MCA articulated arms

•	 Supported software: Nikon Metrology Surveyor / NRK Spatial Analyzer / Tango!3D / Verisurf 

•	 Software development kit (SDK) for 3rd party integrations

 

Environmental requirments

Operating temperature (standard performance) 10°C to 30°C (50°F to 86°F)

Storage temperature -20°C to 50°C (-4°F to 122°F)

Relative humidity 10% to 75% (non-condensing)

Configurations and specifications

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us.nikonmetrology.com

www.nikoninstruments.com

NikoN MEtRoloGy uk ltd.

tel. +44 1332 811349

sales_uk@nikonmetrology.com

NikoN iNStRuMENtS (SHaNGHai) Co. ltd.

tel. +86 21 5836 0050

tel. +86 10 5869 2255 (Beijing office)

tel. +86 20 3882 0550 (Guangzhou office)

NikoN SiNGaPoRE PtE. ltd.

tel. +65 6559 3618

NikoN MalaySia SdN. bHd.

tel. +60 3 7809 3609

NikoN iNStRuMENtS koREa Co. ltd.

tel. +82 2 2186 8400 

iSpace_EN_0410 – Copyright Nikon Metrology NV 2010. All rights reserved. The materials presented here are summary in nature and intended for general information only.
Appendix B: MCA Arm Product Data Sheets
Nikon Metrology offer 110523-DBERRYM-93659-4 Page 4 of 11

Description offer 

MCA II Articulated Arm

The MCA II is a portable manual CMM arm that offers accurate, repeatable and operator-independent inspection 

results for a broad range of applications, along with maximum productivity and maneuverability. It is a precise, reliable 

and comfortable portable measuring system available in 6- or 7-axis versions. Its wireless operation and battery power 

make it feel perfectly at home in the metrology lab, on the shop floor and in the field. 

The MCA II can be equipped with a wide range of probing systems for laser scanning, touch trigger measurements and 

continuous scanning. Its flexibility makes this measurement arm the perfect partner for a wide range of measurement 

tasks. 

Fig 1: 7 axis MCA II (shown with optional MMDx scanner) Fig 2: 6 axis MCA II 

 

Features

 Advanced carbon fiber arm tubes offer strength, light weight, thermal stability and feature a lifetime warranty. 

 Patented infinite rotation of principle axes allows inspection in difficult-to-reach areas. 

 Heidenhain encoders offer “wide-track” bearing support that enhances performance. 

 Rotating grips at elbow and forearm provide low friction grip positions for better ergonomics. 

 An integrated counterbalance reduces operator fatigue and delivers effortless control in all positions. 

 An 802.11g WiFi connection is provided for tactile measuring applications allowing the operator to position the 

computer where it is most convenient. 

 An integrated, rechargeable Li-ION battery allows on-site inspection without AC power or cables. 

 Quick and repeatable change of automatically recognized probes thanks to the TESA kinematic joint adaptor. 

 Ergonomic wrist, incorporating tactile selection buttons with pistol grip on 7-axis arms and integrated camera and 

LED work light on 6-axis arms. 

 The 3.5" x 8 universal mounting system attaches to a variety of tripods and bases - including the standard magnetic 

mount. 

 Accuracy certified according to ASME B89.4.22 standard. 

 “In-the-field” system verification using a NIST-traceable certified length standard included with every arm. 

Technical Specifications

The MCA II comes in both 7-axis and 6-axis variants with diametrical measuring volumes up to 3.6m. The 6-axis MCA 

II comes in two accuracy specifications - Metrology for all applications and Metrology Plus for jobs demanding the very 

highest accuracy. The 7-axis MCA II is available in Metrology-grade spec. 
Nikon Metrology offer 110523-DBERRYM-93659-4 Page 5 of 11

MCA II 7-axis Metrology-grade 

Model Size SPAT 1 Vol length accuracy 2 Weight

MCA II 1800 M7 1.8m (6ft) 0.024mm (0.0009in) 0.035mm (0.0014in) 9.7kg (21.3lbs) 

MCA II 2400 M7 2.4m (8ft) 0.028mm (0.0011in) 0.040mm (0.0016in) 10.1kg (22.4lbs)

MCA II 2800 M7 2.8m (9ft) 0.045mm (0.0018in) 0.064mm (0.0025in) 10.4kg (22.8lbs)

MCA II 3000 M7 3.0m (10ft) 0.050mm (0.0020in) 0.071mm (0.0028in) 10.5kg (23.2lbs)

MCA II 3600 M7 3.6m (12ft) 0.070mm (0.0028in) 0.100mm (0.0040in) 10.9kg (24.1lbs)

 

MCA II 6-axis Metrology-grade 

Model Size SPAT 1 Vol length accuracy 2 Weight

MCA II 1800 M6 1.8m (6ft) 0.016mm (0.0006in) 0.023mm (0.0009in) 9.1kg (20.0lbs) 

MCA II 2400 M6 2.4m (8ft) 0.020mm (0.0008in) 0.029mm (0.0011in) 9.5kg (21.0lbs) 

MCA II 2800 M6 2.8m (9ft) 0.029mm (0.0011in) 0.041mm (0.0016in) 9.8kg (21.6lbs) 

MCA II 3000 M6 3.0m (10ft) 0.034mm (0.0013in) 0.050mm (0.0020in) 9.9kg (21.9lbs) 

MCA II 3600 M6 3.6m (12ft) 0.050mm (0.0020in) 0.068mm (0.0027in) 10.3kg (22.8lbs)

 

MCA II 6-axis Metrology Plus-grade 

Model Size SPAT 1 Vol length accuracy 2 Weight

MCA II 2400 MP6 2.4m (8ft) 0.017mm (0.0007in) 0.025mm (0.0010in) 9.5kg (21.0lbs) 

MCA II 3600 MP6 3.6m (12ft) 0.043mm (0.0017in) 0.058mm (0.0023in) 10.3kg (22.8lbs)

 

(1) Point repeatability Test (also known as Single Point Articulation Test, or S.P.A.T.): results analyzed via range/2 method. The probe is placed within a trihedral seat or 

conical socket, and individual points are measured from multiple approach angles with maximum articulation of all of the principal joints. Each individual point 

measurement is analyzed as a range of deviations about the average value for the point locations. This test is to assess the arm’s ability to provide similar values of a 

point co-ordinate when the arm is articulated through the maximum possible range of motion for that single point. Accuracies are certified according to ASME B89.4.22 

standard. 

 

(2) Volumetric Length Accuracy Test (Volumetric Performance Test): results analyzed via range/2 method. Volumetric Length Accuracy is determined by using certifed 

length standards (included with all arms) that are measured at various locations and orientations throughout the measuring volume. This test most accurately represents 

the reasonable expectations for machine performance in practical measuring applications. The Volumetric Length Accuracy Test is the most appropriate test for 

determining machine accuracy and repeatability since it involves measuring a certifed length standard many times in several locations and orientations and compares the 

resultant measurements to the actual length. Accuracies are certified according to ASME B89.4.22 standard. 

 

General specifications

Operating temperature: 0° to 46°C (32° to 115°F) 

Humidity: 5% - 95% non-condensing 

Vibration (55 to 2000Hz): less than 100ms/s2 (EN 60 068-2-6) 

Shock & Impact (6ms): less than 1000ms/s2 (EN 60 068-2-27) 

Permissible angular acceleration: 105rads/s2 

Power requirement: Universal worldwide voltage 110-240V, Li-ION 7.2V battery (included) 

Connection to PC: USB / Wireless Ethernet Communication (IEEE802.11b/g 54Mbps) 

Certification: CE compliant 
Appendix C: MMD Laser Scanner Product Data Sheets
PRODUCT DESCRIPTION 

The ModelMaker D is the sixth generation of laser scanner from 

Metris, featuring "True Digital Camera Technology", which is a 

leap forward in 3D laser scanning technology and includes 

several groundbreaking innovations that have never previously 

been available on any laser scanner. The ModelMaker D is the 

premium hand-held scanning solution from Metris. 

KEY FEATURES 

 Ultimate productivity 

 No interface box for maximum portability & simple setup

 Total thermal stability – no warming time

 Twin pod design

 Integrated to the latest Metris, Faro and Cimcore articulated 

arms. Integrated to the Metris K-scan.

 Choice of 3 stripe widths (50 mm ,100 mm, 200 mm)

 Scanning rate up to 80 stripes/sec.

 Variable data collection, optimise for speed or resolution

 Manual stripe selection 100/200mm (D200 sensor)

 Arm controlled menu operation

 Real time visualization of scanned data

 Laser spot for stand-off indication

 Lap-top compatible

 Enhanced Sensor Performance (ESP2) for the ultimate in 

improved scanning of non-ideal surfaces (dark or shiny)

APPLICATIONS 

In general the ModelMaker D is designed for the scanning of 

freeform surfaces of components ranging from approximately 

10cm up to 4meters in the sub 100micron accuracy range. 

Feature capture capability is also possible. 

Application segmentation: 

 Inspection – any application where the objective is to check 

or verify the dimensional information of the component being 

scanned against a reference 

O Surface inspection

O Section inspection

O Feature inspection

 Reverse Engineering – any application where the objective is 

the re-create the precise 3D data of the physical part for a 

further process

O Manufacture

O CFD, FEA

O Visualisation

O Digital archiving

TECHNICAL SPECIFICATIONS 

 D50 D100 D200 

Sensor weight (g) 395 

Range Z (mm) 50 100 150 

Max stripe length Y (mm) 50 100 200 

Min point spacing Y (mm) 0.05 0.075 0.100 

Stand-off distance(1) (mm) 100 100 55 

Max stripes / second 80 

Max points / stripe 1000 

Laser power Class 2M 

Sensor dimensions (mm) 179.5 x 75 x 137.5 

(1) Stand-off distance is calculated from the sensor to the beginning of 

the Field of View 

TYPICAL SYSTEM ACCURACY (1) 

System 

Flat plane 

measurement (2)

(2 sigma – 95%) 

Plane to plane 

measurement(3)

(3 sigma – 99.5%) 

D50 0.030 0.050 

D100 0.050 0.075 

D200 0.100 0.100 

(1) Typical result based upon sensor mounted on FARO Platinum 

08-05 or Cimcore 3028i localiser scanning matt white surface 

(2) Using Certified scanning settings and Flat Plane measurement (3) Using Certified scanning settings and Plane to Plane 

measurement MMZ figures are based upon 'Merged' data 

ENVIRONMENTAL CONDITIONS 

Operating temperature (ambient) 0oC to +50 oC 

Storage temperature -20oC to +80 oC 

Relative humidity 80% maximum (non 

condensing) 

ModelMaker D 

DATA SHEET V1.6 25 OCTOBER 2007
DS-MMD-1007 

SYSTEM DIAGRAM 

PC SPECIFICATIONS 

The recommended PC specifications for an MMD scanner are: 

- CPU: Intel Core Duo 2.0 GHz or higher 

- Video Card: 

o NVidia: GeForce with 256 Mb RAM, or 

o ATI: Radeon with 256 Mb RAM 

- 20GB Hard disk 

- Dedicated Ethernet connection 

- 3 x USB port 

- 2048MB RAM 

- CD-ROM drive 

- Windows XP Professional 

- Internet Explorer 6.0 or later 

Non Metris PC’s require an onsite installation. 

LOCALISER COMPATIBILITY 

 MMD 

Metris articulated arms 

Metris MCA 6 and 7 axis (1,8m) D 

Metris MCA 6 and 7 axis (2,4m) D 

Metris MCA 6 and 7 axis (3,0m) D 

Metris MCA 6 and 7 axis (4,0m) D 

Metris MCA 6 and 7 axis (5,0m) D 

Metris Optical CMMs 

Metris K-Scan on K500 D 

Metris K-Scan on K600 D 

Metris K-Scan on K610 D 

3rd Party articulated arms 

Faro Platinum/Titanium 7axis 6ft (1.8m) D 

Faro Platinum/Titanium 7axis 8ft (2.4m) D 

Faro Platinum/Titanium 7axis 10ft (3.0m) D 

Faro Platinum/Titanium 7axis 12ft (3.7m) D 

Romer-Cimcore Infinite 7axis 2.4m D 

Romer-Cimcore Infinite 7axis 2.8m D 

Romer-Cimcore Infinite 7axis 3.0m D 

Romer-Cimcore Infinite 7axis 3.6m D 

SYSTEM INCLUDES 

 Sensor (either D50, D100, D200)

 Power supply

 Alignment cube with 6mm probe calibration piece

 Alignment cube extension (two-piece)

 Surface mount datum cones (24)

 Heavy duty carry case with protective foam insert

MANDATORY ITEMS 

 Arm interface for Metris MCA, Faro, Cimcore or K-scan 

(trigger cable and arm mount)

 KUBE Scan software: 

User friendly data capture with ESP2 tracking of scan 

surface and automated optimisation of sensor settings for 

each individual point, real-time rendered scan visualisation, 

arm driven scan menu, online point processing, play and 

record macro’s, support for multi-site measurements. 

OPTIONAL ITEMS 

 KUBE Tools+

Tactile measurements, advanced datuming & coordinate 

system creation and transformation, data set registration, 

advanced online and offline point processing, mesh creation, 

mesh tools and cross sectioning. 

 KUBE Inspect+

Import of CAD (IGES), surface, section and tactile to CAD 

inspection, online inspection, feature measurement and 

dimensioning, colour plot report generation with fly-outs.

 KUBE Inspect+ CAD importers for 

O VDA

O STEP

O ProEngineer

O CATIA V4

O CATIA V5

 Battery and charger kit

 Numbered floor mount datum cones (24)

 Metris offers competitive pricing on twin or triple MMD laser 

scanner packages.

MMD system diagram 

Lap 

Laptop top

Bulky 

Interface 

Box 

Scanner & Arm Data & Power 

~

Metris HQ 

Geldenaaksebaan 329 

B-3001 Leuven 

Belgium 

tel. +32 16 74 01 01 

fax +32 16 74 01 03 

info@metris.com 

Metris USA 

tel. +1 810 2204360 

sales_us@metris.com 

Metris UK Ltd. 

tel. +44 1332 811349 

sales_uk@metris.com 

Metris Belgium 

tel. +32 16 74 01 01 

sales_belgium@metris.com 

Metris Germany 

tel. +49 6023 91733-0 

sales_germany@metris.com 

Metris France 

tel. +33 4 74 76 64 76 

sales_france@metris.com 

Metris Italia 

tel. +39 11 9635511 

sales_italy@metris.com 

Metris China 

tel. +86 21 6448 1061 

sales_asia@metris.com 

Metris Korea 

tel. +82 31 399 5951 

sales_korea@metris.com 

Metris Japan 

tel. +81 52 709 3877 

sales_japan@metris.com 

Metris India 

tel. +91 11 2275 32 44 

sales_india@metris.com 

More offices and resellers at: www.metris.com