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On August 3rd, 1993, Mark Schaefer founded ADC as an Engineering Design Firm. There were four employees total, and the first office was located on Stoneridge Drive in Waukesha, WI. Within two years, ADC moved to Woodgate Road in Pewaukee.

In 1996 a CGI Machine was purchased and offered the first reverse engineering capabilities. This was a sign of the growth that followed over the next three years as ADC went on to add CNC/Tooling capabilities. In 2001, Mark expanded even more by acquiring ADC’s first plastic injection molding machine. 2001 also marked the year that Mark Schaefer received a professional engineer license and was honored by Small Business Times as a Future 50 winner.

2002 was a big year as ADC expanded our reverse engineering by becoming a beta site for Geomagic software and purchasing our first scanner. We also made a big move and doubled our space by moving to Paul Road, where we remain today.

The following year Mark Schaefer, President, and Jim Marschalek, Vice President, became PTC certified to offer Pro/E (now called CREO) software training.

We now have two 3D printers, a Vanguard SLS and a Stratasys Fortus 400 FDM.

Throughout 2011-2012 we added a Faro Arm to expand on-site scanning capabilities and became an authorized reseller of 3D Systems Products. Not only were we expanding our scanning and reverse engineering departments, but we were also growing our molding capabilities with the acquisition of a JSW 200-ton servo-electric plastic injection molding machine.

In 2015 ADC initiated a remodeling project to create more manufacturing space at our home office at N27 W23655 Paul Road, Pewaukee, WI 53072.

Over the next 8 years, we experienced abundant growth by investing in a dedicated plastic injection molding space next door and adding two brand new 3-Axis Hurco CNC Machining Centers (VMCs), a new large 350-ton JSW plastic molding machine with a part capacity of 1.8 pounds, and invested in a new energy efficient electric Engel plastic injection molding machine: a 120-ton machine with part capacity up to 0.6 pounds.

At our main building, two new smart CNC Machining Centers were installed to expand our tool design services. We also expanded our service line by adding automation solutions.

In 2018 ADC purchased a brand new GOM Scanning System. The model is the ATOS Triple Scan 8M equipped with blue light technology. The narrowband blue light enables precise measurements to be carried out independently of environmental lighting conditions. The ATOS Triple Scan offers even greater resolution and accuracy for fine structures and edges and supplies full-field 3D data for complex components within a very short time.

During this time, ADC also became an ISO 9001:2015 Certified By Verisys Registrars company.

As we continue to grow, ADC looks forward to another 30 years of serving our customers at the highest level!

“SWINGING” into SPRING & BASEBALL SEASON!

Dan Mueller, Pewaukee native, and former college baseball player shared his knowledge and passion for the game by coaching his kid’s baseball teams. Through his personal experience playing ball and coaching, Mueller realized most players struggle with their swing mechanics. Mueller had some ideas on how to help players build muscle memory to improve their swing and took to his garage to develop a solution.

Once Mueller had a product concept, he contacted ADC to help bring the product to fruition. ADC has had the honor of partnering with numerous entrepreneurs to help their product idea a reality and working with Mueller was no exception.

“I approached ADC with the product idea five years ago and the entire team, including Mark Schaefer, the owner, walked us through the whole process from finalizing the product concept to prototyping and engineering to manufacturing it,” said Mueller. The innovative end result – SWINGRAIL!

SWINGRAIL is proven to improve bat speed, power, and swing plane and has done so with 368,000+ baseball and softball users…from little league players to numerous MLB teams across the country and every player in between.

Mueller went on to say, “Our product is now in more than 1,500 retail stores & has been a top-seller on Amazon for the past 4 years! We couldn’t have done it without our partnership with the entire team at ADC.” ADC celebrates SWINGRAIL and its wild success. Learn more at www.swingrail.com  and contact them at dan@swingrail.com.

Three-dimensional (3D) printing is being utilized across many different industries. The technology continues to advance and is becoming commonly used not only in business but in homes and as part of many schools ’curriculums.

A 3D object is created layer by layer. Each layer is a 2D, or flat object. The layers are also referred to as slices; each slice is similar in thickness to a sheet of paper. Instead of being a full rectangular sheet of paper, each layer or slice is a printed shape. The material being printed is typically plastic but can be metal, ceramic and biological materials, just to name a few.

At Advanced Design Concepts, the 3D printing technology is used in prototypes, as well as inspection and assembly fixtures and custom automation and robot components. We have recently had customers seeking rapid prototypes as well as replacements of parts they cannot otherwise acquire, like an antique car or motorcycle parts not in aftermarket production.

ADC remains on the cutting edge of 3D printing technology with our in-house rapid prototyping department.

There are many advantages to 3D printing:

· Customization: each part can be made uniquely for personalization, customization, or testing design options

· Time: a part can be made in hours, rather than waiting weeks for a prototype tool, drastically reducing time to market

· Risk Reduction: 3D printing one or more parts for design verification and fitment testing reduces the risk of costly and timely tooling modifications

· Cost: 3D printing a single part is much less expensive than designing and building a tool, permitting emergent companies and inventors to prove a concept without an overwhelming monetary investment

· Limitless: Our High Definition printers can create parts that are otherwise impossible to manufacture

Any good manufacturer will utilize a quality management system (QMS) to consistently meet customer requirements. Quality control (QC) is especially important during mass-production, if the product does not pass inspection, huge quantities can be rendered waste or scrap. To avoid lost time and material or poor-quality products, inspections must be made throughout the production process. What should be inspected and against what should that inspection be done? Naturally, the design and engineering specifications but, what happens when a nonconformity occurs partially through production or the part/assembly passes in-process inspection and does not fit a mating part? As part of any QMS, what and when inspections occur should be determined before production even begins. Predetermined specifications are the goal of any manufacturer but, they are more theoretical than physical and of little use when undertaking a corrective action process when a non-conformity occurs. A physical baseline is needed for comparison. To achieve that baseline a first article inspection (FAI) is performed.

What is a First Article? After prototype and pre-production phases are completed production can begin. A first article is a sample or part/assembly of the very first production run. A first article represents what can be expected when the item is mass-produced. First articles can be picked at random from the production line, they do not have to be the first part produced. Often one to three units are pulled for first article inspections (FAI), in some instances more units are required. What is a First Article Inspection? A first article inspection (also known as a production process verification) is a method of verifying a manufacturing process.

The FAI may compare:

• all geometric dimensions and characteristics

• appearance/color

• UV resistance

• finish quality

• product identification

• defects

• material

• statutory and regulatory requirements

• fit, form and function

• physical properties – weight, density, stiffness etc.

• insert, bushing, thread requirements to drawings, CAD models and other process requirements to ensure conformity to design. This verification is documented in a first article inspection report or FAIR. A FAI also ensures that operators understand process requirements, tooling is properly calibrated and the process is consistent.

What industries require FAI?

A FAI is not necessary for all parts and products. A FAI is not needed for unique, low quantity, and single production runs as well as, most low-cost consumer and promotional goods. Although, a limited inspection, similar to a FAI may be necessary.

Any products that:

• are expensive to manufacture

• contain expensive components/materials

• are difficult to rework

• have strict tolerancing

• require precision

• involve processes vulnerable to calibration error

• have high safety standards are likely to require a FAI

Industries that manufacture such products typically are:

• Aerospace

• Automotive/Transportation

• Medical • Military and Defense

• Electrical and Electronics

• Energy

• Agriculture

In general, certain industries or companies require a FAI more than others. When is a FAI needed? In the purchase order contract between purchaser and supplier is when a FAI is typically requested. The design stage should be completed and production processes should be determined before a FAI is performed since the FAI is used to verify the production process of the given product. Naturally, during the first run of the product is when a FAI should initially be performed.

Other circumstances may require a FAI such as:

• Design changes. Especially those that affect fit, form and function.

• When the design remains the same but, the materials or manufacturing source change.

• Long periods of time between runs. If any characteristics are affected by inactivity.

• When a sub-component of an assembly has changed that may affect fit or function.

• A change in process that may affect fit, form or function.

• When a tooling change occurs. Repairs of damaged or worn tools.

• When manufacturing is moved to another location/facility.

If the change might affect fit, form or function. Ultimately, a FAI is needed when required by a customer or a company’s QMS. What does a FAIR prove? Performing a FAI and compiling a FAIR provides objective evidence to the customer that manufacturing specifications, processes and repeatability of the part/assembly are understood and achievable.

The FAIR documents and verifies that:

• Engineering and design specification requirements are understood.

• Personnel understand tooling, materials and processes and are capable of producing compliant parts/assemblies consistently.

• Part/assembly baseline, definition, compliance and repeatability are established.

Essentially, the FAIR proves that the part/assembly can and will be manufactured to the customer’s specifications. What measurement methods are used for FAI? Physical, functional and dimensional characteristics are to be verified against drawings, CAD, engineering and other design specifications.

• The use of Go/No-Go gauges, such as plug, ring and snap gauges, can be utilized to accurately inspect dimensions. Though a Go/No-Go gauge does not provide a quantitative measurement, it can limit error and increase speed with a pass or fail determination.

• Hand tools: calipers, bore gauges, fixed gauges, micrometers, protractors, thread gauges, indicators and comparators.

• Coordinate Measuring Machine (CMM), vision systems.

• Arm based laser scanning and probing systems: Faro, Hexagon (Romer).

• Structured light 3D scanners: GOM ATOS Triple Scan, Steinbichler Comet.

• 3D inspection software: Geomagic Control X, GOM Inspect, Polyworks Regardless of the method used, all equipment should have current calibration certificates.

What is the difference between a FAIR and PPAP?

In a way, a FAIR is part of the production part approval process (PPAP). PPAP requirements include dimensional results and material, performance test results. All of which are tested and measured during the FAI process. One key difference is a PPAP may require a higher volume of samples than a typical FAI, 5-10 instead of 1-3. A PPAP may require only critical to quality (CtQ) dimensions be inspected instead of all called out dimensions and specifications. Overall, the focus of a FAIR is on verifying production results against product design. A PPAP covers 18 elements that may be required for submission, process verification included. A PPAP overall is a production plan, including engineering and design documentation/approval, both Design and Process Failure Mode and Effects Analysis (DFMEA and PFMEA), process flow, a control plan, measurement system analysis and other elements to provide evidence that requirements are met and the process is capable of reproducing quality parts consistently.

In other words, a FAIR is focused on material and the resulting part/assembly. A PPAP is more concerned with how that final result is achieved and that it can be produced consistently for extended production periods. Who performs a First Article Inspection? Typically, the responsibility is on the supplier to provide a FAIR. A supplier can perform the FAI in-house provided they are adequately equipped for the task. A purchaser may conduct an audit of a supplier’s QMS against ISO 9001 standards to ensure proper quality control processes. The FAI may also be performed by a third party chosen by the purchaser or the supplier. A professional third-party FAI may also be a preferred option if a supplier is not adequately equipped. In some cases, both the purchaser and supplier will provide a FAIR to ensure consistent results. Ultimately, the customer determines who will perform the FAI in the purchase order contract. Some suppliers will perform a FAI without requirement as a “best practice” to ensure quality and minimize non-conformities. Summary and Benefits.

Other than satisfying contractual agreements a FAI:

• Confirms the production process is capable of creating consistent parts/assemblies to customer requirements.

• Sets a baseline or gold standard for what the production process is capable of. • Aids in the corrective action process when a non-conformity occurs.

• Validates all designs and confirms the tooling is capable of producing the part/assembly within certain specifications.

• Will highlight any manufacturing process flaws.

• Will improve productions processes with regular implementation.

• Will help reduce waste of material and time.

• Will reduce the cost of a part/assembly and increase profitability.

​Sporting Smiles is changing the world one smile at a time. ADC’s design engineers helped Evan McCarthy, the SportingSmiles CEO, to design and manufacture a patented adjustable impression dental tray. According to McCarthy, “We wanted to develop a process that created one-of-a-kind dental products that would be available at a more reasonable price, while still maintaining lab quality. Our self-impression kit allows for new or replacement dental guards to be created directly at our dental facilities, therefore bypassing additional fees that have been associated with custom guards in the past.”

The Dual Arch Adjustable Dental Impression Tray was awarded patent #8,360,772. SportingSmiles specializes in smile retention and enhancement with a wide array of products to alleviate joint pain and prevent injury. Products are available via the SportingSmiles website at https://www.sportingsmiles.com/ or Amazon.​

In middle school, McCarthy was accidentally hit with a wayward baseball bat during gym class.  The result:  he lost four front teeth, but the accident led to today’s successful business. After the accident, McCarthy took care to wear mouth guards when playing sports but he found that over-the-counter guards were “uncomfortable and boring.” McCarthy asked his father, a dentist, to teach him how to make custom guards and began producing some with different colors, patterns, and graphics, drawing interest from family and friends.

Sporting Smiles is in the smile retention business with a wide array of injury prevention and smile enhancement products and celebrating 10 years in business. Fun to see them in the news this recently! Designed for MMA, Jiu-jitsu, football, basketball, hockey, and other contact sports.

At ADC we preserve client confidentiality.  All the information and photos shared in this newsletter, shared with permission.

 

 

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1. 3D Scanning: The Process Of Turning A Part Into A 3D Model

Much like a camera takes photos of the real world in two dimensions, structured light scanners capture images of the real world in three dimensions.

A fringe pattern, or series of lines, is projected onto an object. The lines curve and distort as they lay on the contours and surfaces of the part. Two cameras work in tandem to capture this image and 3D scanning software processes the image using complex computations to create a digitized 3D snapshot.

Just like a regular camera, the scanner can only take one still image at a time. Target points placed on and around the object allow the software to triangulate its orientation and location within a three dimensional coordinate system. Many individual images must be taken to fully encompass the part.

The images are then assembled into a “point cloud” or millions of individual points in space. Finally, the points are connected and tessellated into a polygonal representation of the real-life object with an accuracy of up to .001”.

2. Inspection: What Can I Expect From An Inspection?

After a part is 3D scanned and converted into an .STL file it is imported into inspection software along with the corresponding CAD file. Whether the part was scanned in a “free” (natural) or “fixed” (constrained) state the scan will first be aligned to the CAD file via the designated alignment requirements.

Based on part drawings and/or customer requests, parts can be aligned in many different ways: feature based datum alignments, best fit, datum and best fit combinations, RPS, 3-2-1, or transform alignments. Once aligned, an overall surface profile inspection is performed.

A uniform boundary is defined around the part’s entire surface both above and below the CAD or “nominal” surface. The resulting image is a color-plot of the part with green denoting areas that are within tolerance, warm colors (yellow, orange and red) depicting areas that are above the defined tolerance zone and cold colors (blues) showing areas that are under tolerance.

For many parts an overall surface profile inspection is adequate because, it simultaneously measures form, size, orientation and sometimes location within a specified tolerance. For more in-depth inspections local profile zones, 2D profiles and thickness inspections can be performed.

Many GD&T call-outs are measurable such as, flatness, cylindricity, parallelism, perpendicularity, position, concentricity, run-out and dimensions. Once completed, the results are then compiled into a report. For multiple part inspections the process is then repeated and copies of all reports and scan files are sent to customer.

3. Reverse Engineering: How Is A 3D Computer Model Created From A Physical Part

Once the need for a CAD model is determined the reverse engineering process can begin. First, an .STL file is generated by scanning the physical part. A Non-Uniform Rational Basis Spline (NURBS) surface is suitable when a static `true to life’ model is desired.

The .STL file is, in essence, “digitally shrink wrapped” to create a model of the desired geometry along with organic qualities such as warp and imperfections. Many imperfections and defects can be minimized with a NURBS surface making them versatile models ideal for sand cores.

When a more prismatic “perfect” model is needed the part scan can be imported into a CAD package. A new model is created by overlaying the part’s actual geometry.

Manufacturing intent can be applied to the model for tooling and machining purposes. It is possible for the model to be fully parametric when future design changes are anticipated.

4. Determine Your Business Need: What Do You Want From 3D Scanning Services?

A 3D digitized representation of an object provides the foundation for a multitude of services such as Reverse Engineering and Quality Control.

Reverse engineering: create machinable models for replacing old tooling, sand cores, recreating discontinued products, preserving art/history, 3D printing, creating CAD models of parts that never had one, scaling or altering existing items and more.

Quality Control: GD&T inspections, multiple part comparisons, PPAP inspections and more.

5. Timeframe: When Do You Need The Part Scanned?

Upon receipt of the part, Scanning and Inspection work can typically take 2-3 business days depending on quantity, part complexity and scope of work. Larger quantities of 5 or more, larger parts such as airplanes and more complex inspections (full dimensional layouts) may add additional work time.

Reverse engineering usually takes around 3-6 business days and will be dependent on the scope of work, NURBS surfacing vs. fully parametric modeling.

6. Location: Shipping The Part Or Performing The Work On Premises

Shipping: Typically parts that fit on a standard size pallet can be received 3D scanned in-house using both high resolution structured blue light scanners and blue laser light coordinate measuring machine (CMM) arm scanners. Other large components that are deliverable can be scanned such as cars, trucks and other large objects.

On-Site: For objects too large, delicate, important to production, secret or time sensitive the 3D scanning equipment can travel to the location of the part. Cars, airplanes, construction equipment, works of art, large castings and production tooling can be scanned on-site without moving, uninstalling or disturbing the part.

7. Budget: What Is The Scope Of Work Required?

Whether it is 3D scanning for the sake of art preservation, quality control or reverse engineering, having a customized engineering plan for part inspection or reverse engineering will help ensure you meet your budgetary requirements.

From surface profile color-plots, geometric dimensioning and tolerancing (GD&T) dimensional layouts and Production Part Approval Process (PPAP) inspections there is a wide range of quality control services available. NURBS surfacing provides a quick and `true to life’ reverse engineering model. Accurate prismatic model services are available as non-parametric and fully-parametric.

8. Output File And CAD Requirements: Which CAD Package Do You Use?

When a part is scanned it is measured as a point cloud. The point cloud is then polygonized into a geometric mesh known as an .STL (stereolithography) file. Parametric models can be constructed in both PTC Creo (Pro/e) and Solidworks.

Universal, non-parametric models can be provided in many formats including: .STP and .IGES.

9. Cleaning And Part Preparation: What Will Happen To My Part During Scanning?

ADC utilizes non-destructive laser and structured blue light scanning technology. Heavy dirt and oil will be removed with non-harmful cleaning products prior to the 3D scanning process ensuring delicate surface finishes are left intact.

Blue light technology can capture a variety of surface finishes without any special treatment, including many cast surfaces, light colored plastics and other light matte finishes. Shiny and dark surfaces, by nature, reflect too much or not enough light making it difficult to fully capture.

In many cases the object must be coated with developer spray (talcum powder) or even white spray paint when possible. The use of adhesive target points may be necessary as well. External surface capturing is adequate for most applications.

More complicated parts, such as investment castings, may need to be sectioned by destructive means to expose internal geometry for 3D capturing. The whole exterior is scanned first, then the individual pieces after sectioning. All scan files are assembled into a single representation of the object inside and out making for a more complete inspection or reverse engineering project.

Onsite scanning requires hard and level ground to support the scanning machines and enough space to move the equipment around. Once the item is scanned, target points are easily removed and the developer spray is washed off leaving your part in the same state as before the process began.

ADC is The Newest Representative of WinCast Expert in The US

Permanent Die Casting

• CAD Geometry
• Temperature Field
• Filling Velocity
• Stress
• Deformation
• Hot Spot
• Tensile Strength
• Elongation
• Yield Strength
• Defects (ASTM)

Sand Casting

• The total riser and gating system, filter and core are the part of the model
• Precise physical data for exothermic materials are available
• Graphite expansion and precise defect prediction are typical requirements
• Validation with experiments is fundamental for good simulation results

High Pressure Die Casting

• CAD Data
• FEM Model
• Mold Filling
• Solidification
• Residual Stress
• Cycle Calculation

The simulation of solidification is the base for the prediction of porosities, residual stress and deformation.  Several cycles are calculated to draw near the steady state.

Low Pressure Die Casting

• Process Optimization
• Mechanical Properties
• Cooling Calculation
• Defect Calculation
• Pressure-time Input
• Dendrite Arm Spacing

Investment Casting

Precise geometry with high level of detail is the reason for real success.
Optimized riser and gating system leads to a minimal deformed part.  Simulation of temperature, solidification, stress and deformation are the keys to reach optimum.

Continuous Casting

The thermal and mechanical equations are coupled.  Thus the material flow and the shrinkage of the billet can be determined as well as the gap formation and gap dependent heat transfer.

• Primary and secondary cooling
• Material and heat transport
• Pull (and push) conditions
• Contact between strand and graphite chill
• Contact between graphite and copper chill
• Heat transport within cooling lines

Heat Treatment

The changing residual stresses while heat treatment can be calculated in order to optimize the oven curve to reduce deformation.

Stress/Distortion/Lifetime

High differences in temperature during a high pressure die casting cycle and enormous pressure peaks are the reasons for local cracking in the die and reduce the lifetime significantly.

Evaluation of Mechanical Properties

Complex thin-walled aluminum casting.

Stress and Crack Investigation

Fast. Precise. Easy to Handle.

“iFit Prosthetics is an extraordinary ADC client. We have worked with Tim and the iFit Prosthetics team since their product’s inception and found them to be receptive and enthusiastic to utilize and embrace ADC’s full suite of capabilities including: 3D Scanning, Finite Element Analysis (FEA), 3D Printing, and more recently, topology optimization. They understand the engineering principles required to design and manufacture an adjustable prosthetic device.” – Jim Marchalek, ADC

ADC was featured in ScienceDirect for their design of iFit Prosthetics. Click here to read more.

Dr. Dillingham served in the U.S. Army during the Persian Gulf War and served as an investigator for the National Institute for Health (NIH) studying the needs of patients with limb loss. He was amazed by the time and effort required to make a hard socket fit a changing limb. He was inspired to expand the options available to lower limb amputees.

“The design characteristics – adjustability and immediate fit – can potentially enhance access and availability to prosthetic services for many patients. I am grateful for Jim Marschalek’s engineering leadership and the entire ADC team for our partnership in developing the iFit Prosthetics’ product line.”

– Timothy R. Dillingham, M.D., M.S., President, iFIT Prosthetics, LLC

 

Using his engineering, industrial, and manufacturing background as well as his medical expertise, Dr. Dillingham developed a prosthetic that would better adjust to the individualized needs of patients. He turned to Advanced Design Concepts to provide critical engineering support from the beginning of the product development cycle. ADC’s engineering and manufacturing teams, led by Jim Marschalek, have collaborated with Dr. Dilingham to develop and manufacture this innovative, adjustable, affordable lower limb prosthetic. iFit Prosthetics is officially in the life-changing business, improving the quality of life for patients.

 

Diana recently discovered iFit Prosthetics. She faced tremendous challenges finding the right fit for her prosthetic need. According to Diana, “The iFit Prosthetics socket system has given me hope. I have a VERY challenging limb and the adjustable iFit Prosthetic was the one that worked for me when the others have only brought me disappointment. I was on the brink of surgery to have an above knee amputation due to the tremendous pain of other sockets. With my iFit Prosthetic I have resumed my normal life without surgery. Thank you for changing my life and eliminating the pain.” Diana’s is one of many success stories the team at iFit Prosthetics hears from patients.

 

Advanced Design Concepts is proud to have supported the iFit Prosthetic product development cycle since its infancy. Our engineers collaborated with Dr. Dillingham to design, refine, develop prototypes and prosthetic limb, resulting in the current lower limb prosthetic on the market today. Not only have we helped in the development stage, we are also manufacturing elements of the device. All of the strong plastic component parts are injection molded at ADC and assembled at our facility in Pewaukee, Wisconsin. iFit Prosthetics intentionally sources any component not manufactured at ADC using U.S.-based vendor companies.

“ADC has responded with lightning speed as iFit Prosthetics has worked to improve the devices accessibility to patient needs” remarked Dr. Dillingham.

 

SpeedKore Performance Group is a Wisconsin-based company specializing in the construction of custom cars; as well as designing and manufacturing carbon fiber parts. They manufacture high-performance vehicles from scratch following their signature recipe: reduced weight and increased horsepower.

Advanced Design Concepts is extremely proud to have supported SpeedKore in their design process from scanning entire cars to individual pieces such as bumpers, spoilers, engines, transmissions, and interior parts. 3D scanning and reverse engineering technology enable the ADC designers and engineers to scan any custom vehicle or part produced by SpeedKore ultimately resulting in a 3D model of the physical part. 3D digitizing converts physical objects to 3D CAD files to refine designs that enable manufacturing, 3D printing, and inspection.

To date, one of the most noteworthy vehicles to be conceived by the designers at SpeedKore is the 1970 Dodge Charger, “Evolution.” With a full carbon fiber body and a 966 horsepower Dodge Demon engine, the vehicle has not only won the esteemed Goodguys Gold Award but has also made several appearances in television shows and blockbuster movies.

In addition to the success of Evolution, the 1970 Ford Mustang Boss 302 created for revered actor Robert Downey Jr. was awarded the Ford Design Award for Best Heritage Vehicle in 2017. With such prestigious clientele and a reputation of exceeding customer expectations, SpeedKore is tasked with continuing to stand by their company promise of reducing weight and increasing horsepower; while constructing a truly unique vehicle fit for a superhero.

Being in the business of creating custom vehicles, SpeedKore enlisted the help of ADC to aid them in designing molds for carbon fiber body panels, engine covers, and much more. We provide SpeedKore, and every client of ours, with the highest quality of products with the aid of our GOM ATOS Triple Scan 3D scanner. Additionally, ADC has a variety of scanners at our disposal which allow us to get into the tight areas of engine bays as well as the interior of cars.

One-of-a-kind custom cars and parts are in safe hands here at ADC during the scanning process as easily removable target point stickers are applied with no damage to the vehicle. At times a developer powder may be used on shiny or reflective surfaces which can effortlessly be washed off leaving your part exactly as it was prior to scanning.

At ADC, we are flexible and understanding of the needs of our customers and have the ability to receive customer parts to be scanned in-house, or we can travel to you, transporting the 3D scanning equipment directly to the location of our customer’s parts. Our ability to travel directly to the location of our customers is not only advantageous when the part is large but is also convenient for fragile, confidential or time-sensitive parts. We recently traveled to SpeedKore’s facility to scan the exterior of a car, engine bay, bumpers, and spoiler.

Using the ATOS Triple Scan and the Faro Scan Edge Arm, ADC’s scanning team successfully completed all required scanning in a day and a half. The result: physical car to point cloud data. After scanning a car we can provide customers with the raw scan data as an .stl file or an .igs or .stp CAD model.

Dependent upon the scope of the project, ADC may be able to provide the .stl file to SpeedKore right onsite. For particularly extensive projects, a trip to ADC’s office may be necessary to clean up data and align to a world coordinate system before providing files. ADC’s turnaround process is relatively quick, typically scan data can be converted to a CAD model within 1-5 days. Allow our team at ADC the pleasure of assisting you in bringing your project into a 3D reality.