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Cross Sectional Scanning

How It Works

The CGI RE1000 Cross Sectional Scanning (CSS) system accurately collects the data of typically cast or molded components with complex internal geometries in a unique manner that coordinate measurement machines and optical scanning systems cannot analyze due to their inherent methodologies. The CSS system scans opposing geometries (front and back) as well as the internal geometry simultaneously. Multiple parts can be processed at the same time as long as the parts’ material and color are consistent.


The CSS process starts by encapsulating or potting the components in a proprietary epoxy material of a contrasting color. Black or dark parts are encapsulated in a white epoxy, and white or lighter components are encapsulated in black epoxy. For multicolor parts, a red epoxy is used.


The CSS system uses an industrial grade face mill to accurately machine away ultra-thin layers of a part encapsulated in epoxy of a contrasting color, exposing the profile between the component and the epoxy.

The hardened epoxy both reinforces the internal and external walls of the part and provides the required high color contrast. The CSS scanner utilizes the color contrast to define the part’s geometric contours and ultimately to generate a 3D image of the component.

3D Scanning

After each successive layer is machined away, the CSS system using its optical scanner and software captures, collects, and assembles each newly exposed 3D image into the part’s 3D database. This destructive milling, scanning, and building process continues all the way through the entire part.

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