How 3D Scan STL Revolutionizes Reverse Engineering

3D scanning and reverse engineering are transforming industries from manufacturing to healthcare. Michael Netherton placed himself at the forefront of this transformation. Through his company, 3D Scan STL, he makes sure to deliver high-precision 3D models that empower businesses to innovate and excel.

In this exclusive interview, we delve into Michael’s journey into the realm of 3D scanning, explore the challenges and triumphs of building a successful business in this specialized field, and gain insights into the future of 3D scanning and reverse engineering. Join us as we uncover the story behind 3D Scan STL and its impact on the technological landscape.

SBS – What sparked your interest in 3D scanning and reverse engineering?

Michael – Before I got into 3D scanning and reverse engineering, I was the owner and president of Responder Public Safety Equipment. RPSE was in its thirteenth year of operation, selling and installing emergency vehicle equipment. I wanted to set my company apart from the rest by scanning police cars and developing custom mounting solutions for the LED warning lights typically mounted on the exterior of these vehicles. To that end, I started 3D Scan STL, LLC (3DS), purchased an Artec Eva handheld 3D scanner, and began the long learning curve of becoming highly proficient.

SBS – How do you ensure the accuracy and precision of your 3D models?

Michael – It starts with the hardware and software used to create the models. There is a reason the Eva is substantially more expensive than most other handheld scanners. I spent a great deal of time researching hardware and software before choosing the Eva specifically for this reason. 

When scanning an object where special accuracy is very important, I have the ability to verify measurements in the scanning software by physically measuring the part. I have only had one object fail to render the correct measurements. It was the deck of a 35’ cabin cruiser. I thought the deck had enough surface detail with which to capture it accurately. There was enough detail for the human eye, but the software was unable to align the scans accurately. The model ended up being too small by nearly ten percent. Lesson learned. Scanning the boat a second time, additional visual “texture” markers were applied to the deck so the software would have strong reference points with which to align the scans. The second model was dead on, and the ship repair facility was able to get the new deck cut and installed using the measurements from the second scan.

SBS – What industries benefit most from your services, and why?

Michael – The markets that have brought in the most work have been in transportation (cars, trucks & boats), artwork (sculptures and figurines), and industrial parts (dies). Transportation is a natural fit for this technology. With the need to develop new parts for existing products or just accurately document an obsolete part for re-production, 3D scanning and reverse engineering fill this need perfectly.

For artwork, archival, reproduction, and scaling have been in high demand, the biggest being prototyping and scaling. One of our clients specializes in developing sculptures on commission. These sculptures are typically very small-scale, for obvious reasons. After the prototype is complete, it is scanned and modeled, usually with the texture, for the artist’s client(s) to view and approve before creating the final full-scale work. 

A great deal of the current industry grew from the pre-computer era when everything was drawn by hand. Computer-aided drafting (CAD) simply did not exist. In addition, not all of the mechanical drawings were preserved. For these clients, we are able to take an object, such as a machine die, scan it, and convert it to CAD in a way that is efficient & cost-effective.

SBS – What was the most significant turning point in growing your business?

Michael – It was the day the 3DS website reached number one for 3D scanning in St. Louis in the organic search engine results. Leveraging my extensive background in IT, web development, programming and SEO, I was able to reach the top spot by spending money to advertise. From there, calls and emails began streaming in. This is when I knew 3DS was close to producing substantial income.

SBS – How do you manage client expectations when it comes to turnaround time and costs?

Michael – I try to be very clear from the start about what a client can/should expect with regard to these issues. I rarely bill more than a job is quoted; however, it does happen. Sometimes, jobs end up being more work than anticipated due to issues not visible early on, for which I have no control. When this happens, I usually let the client know the cost will be more than quoted to avoid a shock when the job is done. When something happens on my end, I let the client know there may be a delay in delivery, but the bill doesn’t change just because I missed something I should have seen/anticipated.

As for turnaround times, I have enough experience to know how long something will take to scan and model. I always give a window for completion to allow for the unexpected, but usually, I’m able to deliver early or on time.

SBS – How do you maintain quality control across different types of 3D scanning projects?

Michael – This is actually pretty easy. I have become very proficient in the art of scanning and creating 3D models. The hardware and software do most of the work. Whether it’s a tiny medical device or a complete vehicle, it’s knowing the capabilities and limitations of the hardware. Basically, if I can see it, I can scan it — and do so very well.

SBS – How do you approach customer relationships in a highly specialized field like 3D scanning?

Michael – The great thing about working in this industry, being someone who has ADHD and Asperger’s, is that I am always in my element. Clients understand that this is a very technology-driven service and appreciate it when I’m able to take something that seems to be magic and make it understandable for them. In addition, I like to follow up with my clients to make sure the work they’ve received meets their expectations. In the very few cases where it wasn’t the case, I’ve done whatever was necessary to correct any mistake or misunderstanding.

SBS – How do you see the future of 3D scanning and reverse engineering evolving?

Michael – Eventually, I think there will come a time when something can be scanned with a phone and an accurate CAD model created on the spot, although I don’t see it happening in my lifetime. Just as the cell phone replaced the landline, the technology will become ubiquitous and simply taken for granted. In the meantime, I think more and more people will come to see and understand the benefits of this service, seeking out skilled providers to deliver high-quality results. I expect to earn a substantial income in this business and establish myself as an expert in the Greater Metro Area.

SBS – What are the biggest misconceptions people have about 3D scanning and reverse engineering?

Michael – That they can buy a $300 or even $1,000 scanner and do it themselves. This is more of an art than a science, and a lot of people are lured in by the slick advertising, making it appear that anyone with a cheap scanner can achieve outstanding results. In this case, you really do get what you pay for. For a hobbyist who wants to scan dungeons and dragons or Jurassic Park figurines, they can be a lot of fun. Anyone who needs high-quality, accurate results has to be willing to invest in the hardware and software necessary to achieve those results.

SBS – Can you describe the most innovative application of 3D scanning you’ve seen?

Michael – The process and the results are pretty straightforward. If something is being scanned into a 3D model, it’s because the object already exists. There are several technologies available to achieve the desired result.

SBS – In your opinion, what is the next big thing in the 3D scanning industry?

Michael – New software has recently been released that allows someone to create an accurate 3D model just by taking pictures with a phone. This has been around for a couple of years, but the technology and the results were very poor. It’s a lot more work than scanning, but it can be used in situations where scanning is not feasible or practical. It’s not a “game-changer,” but it is a very handy alternative for those who have the deep pockets to purchase the software.

SBS – What advice would you give to entrepreneurs thinking about entering the 3D technology space?

Michael – There are two paths into this space. The first is having deep pockets and the ability to pay the bills for a year or more without relying on the income generated by scanning. It takes a lot of time to cultivate clients and to become proficient with the hardware & software. If you’re in a very large city, there is a greater chance of success just because there will be a large market available. If you’re in a small city, such as St. Louis, the demand is not nearly as great. This was the path I was able to follow.

The second path is starting small, purchasing consumer-grade hardware & software so as to become proficient with the technology. From here, someone can grow small clients into larger clients as they purchase professional-grade hardware & software. Thereby growing their own business. 

Either way, unless someone has a ready-made market set to tap into, the technology still presents a significant barrier to entry into the 3D space. The person starting out should not expect to earn a living right out of the gate, so to speak.