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3D scanning and reverse engineering used to create a Berlinetta Effeffe

The use of innovative technologies such as 3D scanning and reverse engineering can play a huge role in the direct production of a classic dream car such as the Berlinetta Effeffe, handcrafted by Officine Fratelli Frigerio. Through the support of leading experts at The 3D Group (Solid Energy for 3D scanning and reverse engineering, Solid World for CAD 3D modeling and Energy Group, for 3D printing) digital manufacturing showed that it can perfectly blend with the Made in Italy style in automotive maufacturing.
static1.squarespaceThe Berlinetta Effeffe (www.effeffecars.com) represents a masterpiece of Made in Italy automotive style and engineering. It is inspired by the legendary 50’s Gran Turismo years yet extremely modern, born out of the passion and the experience of Leonardo and Vittorio Frigerio. This dream this is made entirely by hand by the utmost traditional handcraft, while, at the same time, it leverages on a high-quality craftsmanship process, supported by the most modern technologies.

This new high-tech and craftsmanship blend benefits from the use of the most innovative technologies in digital manufacturing, such as 3D scanning, reverse engineering processess and 3D printing, which optimize the production process without sacrificing details and quality.

From the past to the future and back
The project is the Frigerio brothers’ brainchild, achieved by combining the skills of expert craftsmen who have created, by shaping sheetmetal, a true work of art. An idea that was born as a game ans has attracted the interest of many fans. So, as we so often see with 3D printing, the game became a real product. Digital manufacturing enabled the Frigerio brothers to speed up product development, from the design stage through to production. It enabled artisans to actually work on an industrial scale, while achieving a drastic reduction in costs.

The digital data capture is an important step in this project, where the scanning and reconstruction of the 3D model are the first phases of a “car virtualization” process necessary for its engineering. From the 3D model, the Figerio brothers were able to design and create tools for their specific needs. These tools were then created through additive manufacturing using Stratasys FDM technology, thus resulting in further time and cost savings, as compared to the use of traditional processing techniques .

The Hexagon 3D scanner used for the reverse engineering process
The Hexagon 3D scanner used for the reverse engineering process

Catching a classic geometry on the fly
The data capture of the Berlinetta Effeffe geometry was carried out in a few hours directly at the Officine FratelliFrigerio, by using the portable 3D scanner Hexagon Metrology Q-Flash. The mesh obtained through the PolyWorks Software for reverse engineering  (developed by InnovMetric Software Inc, Canada), was subsequently imported into Solid Works for reconstruction and engineering.

A scaled down 3D printed prototype of the Berlinetta Effeffe was recently exhibited at the MESCPE show in Parma at the Energy Group stand. This prototype was used as a clay mock-up to observe and correct any defects before going into production. The Energy Group team working on the project has made a major contribution through the mastery of innovative technologies such as 3D scanning and 3D printing, adding an in-depth knowledge of the entire workflow.

This knowledge can enable small businesses to gain a competitive advantage from the use of digital manufacturing as well as to fully very both the process and the project, before going into production, dramatically reducing time and costs. The best part is that high-end traditional craftmanship is the segment that stands to gain the most from these new and amazing digital manufacturing technologies.

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