Buyer’s Guide · 3D Scanners
5 Things to Look for in a 3D Scanner
There is no single scanner that is right for every job. Before you compare spec sheets, define your application — then weigh accuracy, speed, support, ease of use, and real-world value.
Choosing the right 3D scanner can be a difficult process. There are dozens of systems on the market, a wide range of technologies, and scanner specifications that can sometimes be confusing or even misleading if you do not know exactly what to look for.
One manufacturer may advertise extremely high accuracy. Another may promote millions of measurements per second. Some systems focus on portability, while others emphasize resolution, automation, or ease of use.
The problem is that there is no single 3D scanner that is perfect for every application. A system that is ideal for inspecting precision machined aerospace components may be a poor choice for scanning complete vehicles. Likewise, a 3D scanner designed to capture a 30-foot industrial casting may not be the right technology for reverse engineering a small medical component.
Before comparing specifications and requesting demonstrations, companies should first take a step back and clearly define what they actually need from a 3D scanning system.
At EMS3D, we have worked with companies in aerospace, automotive, manufacturing, marine, energy, defense, and numerous other industries to implement professional 3D scanning and metrology technology. One of the biggest mistakes we see is companies immediately focusing on a scanner model or advertised specification before thoroughly evaluating their application.
In this article, we will discuss the five most important things to look for when buying a 3D scanner:
- Accuracy and precision
- Scanning speed and total workflow time
- Service, training, and technical support
- Portability and ease of use
- Overall value and return on investment
Before examining these five areas, however, there are several important questions every company should ask.
Before Buying a 3D Scanner, Define Your Application
The process of selecting a 3D scanner should begin with the application, not the scanner.
It can be tempting to look at a manufacturer’s website, review a specification sheet, and immediately start comparing accuracy numbers or scan rates. Unfortunately, these specifications provide very little value if the system does not match the type of work your company performs.
Start by evaluating the parts and projects you expect to scan.
What Size Parts Will You 3D Scan?
Part size is one of the first considerations when choosing a 3D scanner.
Are you primarily scanning very small components? Do you work with medium-sized machined parts? Are you scanning automotive panels, molds, castings, or complete assemblies? Do you need to measure extremely large objects such as aircraft, boats, tanks, structures, or heavy equipment?
Perhaps more importantly, do you need a scanner that can handle a wide range of part sizes?
Some companies perform extremely repetitive work. They may inspect the same family of small machined components every day. In this situation, a highly specialized system may make sense. Other companies have a much broader range of applications. A service provider, engineering company, or job shop may scan a six-inch component in the morning and a complete vehicle in the afternoon.
For these users, versatility can be extremely important. Understanding your typical minimum and maximum part sizes will quickly help narrow the range of appropriate 3D scanning technologies.
What Types of Parts Are You Scanning?
Size is only part of the equation. You also need to evaluate the physical characteristics of the objects you plan to scan.
Are the parts mostly simple prismatic shapes with planes, cylinders, and holes? Or do they contain highly complex organic and freeform surfaces? Do your parts have numerous small features? Are they extremely shiny? Are they dark black? Do they have highly contrasting colors? Are they translucent or transparent? Do they contain deep cavities, recessed areas, or difficult-to-access features?
Different 3D scanning technologies respond differently to these conditions. For example, a scanner may produce outstanding results on a white matte reference object during a controlled demonstration. That does not necessarily mean the same scanner will perform equally well on a polished aluminum casting or a glossy black carbon fiber component.
Real-world part conditions matter. When evaluating a scanner, you should test the technology on components that accurately represent your normal applications.
Where Will the 3D Scanner Be Used?
The operating environment can have a major impact on scanner selection.
Will the system remain in a clean, temperature-controlled inspection laboratory? Will it be used on a production floor? Do you need to scan near large CNC machines or manufacturing equipment? Will the environment contain dust, dirt, oil, or vibration? Could the scanner be exposed to heat or humidity? Will you need to scan outdoors?
Some users may need to operate in direct sunlight or in areas without controlled lighting. These are very different conditions from a metrology laboratory.
A system that performs extremely well on a granite table in a climate-controlled inspection room may not be the best system for scanning a large weldment on an active production floor. You should always consider the real operating conditions in which the scanner will be used.
Will You Need to Travel With the 3D Scanner?
Portability requirements should also be considered early in the selection process.
Will the scanner remain in the same room for its entire life? Will it need to move between departments within your facility? Do you need to transport the scanner between multiple company locations? Will technicians travel with the scanner in a vehicle? Will the system need to be shipped across the country or internationally?
A 3D scanning system may include considerably more than the scanner itself. Depending on the technology, the complete system could require:
- Tripods
- Heavy bases
- Calibration artifacts
- Positioning equipment
- Targets
- Reference spheres
- Control units
- Multiple cases
- Specialized computers
- Granite or vibration-isolated tables
When evaluating portability, look at the entire system rather than just the scanner head.
What Applications Will You Use the Scanner For?
You should also identify the actual engineering applications the 3D scanner needs to support. Common applications include:
- Reverse engineering
- 3D inspection
- Quality control
- Dimensional inspection
- GD&T inspection
- First article inspection
- Tooling verification
- Deformation analysis
- Digital archiving
- Product development
- CAD comparison
- Basic dimensional measurements
Some users primarily need polygon mesh data for reverse engineering. Others may require full GD&T inspection and traceable metrology workflows. Some companies need both.
Your application will affect not only the scanner you select but also the software, training, and operator skill level required.
Who Will Operate the 3D Scanner?
The skill level of the operators should never be overlooked.
Does your company already employ experienced CAD designers? Do you have dedicated metrologists? Are the operators familiar with engineering drawings and GD&T? Will machinists or manufacturing engineers use the system? Or does the scanner need to be accessible to a larger group of employees with limited metrology experience?
A complicated scanner that only one highly trained employee can operate may create a bottleneck. When that employee is unavailable, the equipment may sit unused.
On the other hand, a company performing advanced aerospace inspection may require a highly technical system operated by experienced metrology personnel. The correct level of complexity depends on the organization and the application.
Should You Buy a 3D Scanner or Outsource the Work?
Another important question is how frequently you will use the scanner.
Do you currently outsource significant amounts of 3D scanning, reverse engineering, or inspection work? Could owning a scanner reduce lead times? Are engineering projects being delayed while you wait for outside measurement services? Could a 3D scanner solve recurring manufacturing or quality problems? Or would owning a scanner simply be convenient a few times per year?
There is nothing wrong with outsourcing 3D scanning. For occasional projects, professional 3D scanning services may be significantly more cost-effective than purchasing equipment.
However, if scanning is becoming a regular part of your product development, quality, or manufacturing workflow, bringing the technology in-house can potentially provide a much stronger return on investment.
Once these basic questions have been answered, you can begin evaluating the five major characteristics of a 3D scanning system.
3D Scanner Accuracy and Precision
Accuracy is almost always one of the first topics discussed when evaluating a 3D scanner. The obvious question is:
How accurate is the scanner?
Unfortunately, the answer is not always as straightforward as it sounds. One of the biggest areas of confusion in the 3D scanning industry is the difference between accuracy and resolution. These terms are sometimes used interchangeably, but they describe very different characteristics.
3D Scanner Accuracy vs. Resolution
Accuracy describes how closely a measurement represents the true physical geometry of an object. Resolution is related to the level of detail or sampling density the system can capture.
A scanner can have relatively low resolution and still produce accurate measurements. Likewise, a scan can appear extremely smooth and detailed on a computer screen while being dimensionally inaccurate.
Imagine scanning a circular object. The resulting mesh may appear very faceted, with relatively large triangles. Visually, someone might look at the scan and immediately assume it is inaccurate. However, if you fit a mathematically perfect circle through the measured vertices, those individual points may actually fall very close to the true physical circle. The scan has lower resolution, but the measured data may still be accurate.
Now consider the opposite example. A scanner produces a very dense mesh with thousands of small triangles. The model looks smooth and visually impressive. However, the measured surface may be offset from the true geometry. The scan has high resolution, but poor dimensional accuracy.
This is why evaluating a scanner based solely on how the data looks on a computer monitor can be misleading.
Resolution relates to surface detail. It is not automatically the same as accuracy.
Both characteristics can be important, but they need to be evaluated independently.
Accuracy, Precision, and Repeatability
Precision is another important consideration. In practical terms, precision is closely associated with measurement repeatability.
Imagine measuring the same feature multiple times. If the results are spread over a wide range, the measurement process has poor precision. If the results are tightly grouped, the system demonstrates better repeatability.
However, highly repeatable measurements can still be wrong. A scanner could repeatedly measure a 25.000 mm feature as 25.100 mm. The measurements are extremely consistent, but they are consistently inaccurate.
Ideally, a measurement system should provide both high accuracy and good precision. This concept becomes increasingly important when companies perform Gauge R&R studies or evaluate a measurement process using multiple operators, multiple systems, and different environmental conditions.
A single accuracy specification on a brochure does not necessarily tell you how the system will perform in your facility with your parts and your operators.
How Much 3D Scanner Accuracy Do You Actually Need?
This is one of the most important questions a buyer can ask. More accuracy generally costs more money. The cost difference may become substantial as measurement requirements become more demanding.
A scanner designed to measure within approximately 100 microns is generally a very different system from one designed for 10-micron applications. As accuracy requirements become tighter, equipment can become exponentially more expensive.
The scanning process may also become more controlled. Higher accuracy applications can potentially require:
- More stable environmental conditions
- More frequent calibration
- More controlled setups
- Higher operator skill levels
- Specialized fixtures
- Additional equipment
The goal should not necessarily be to purchase the most accurate scanner you can afford. The goal is to purchase a scanner that can reliably meet your actual measurement requirements.
Buying far more accuracy than your application requires may increase equipment cost and complexity without adding meaningful value. On the other hand, purchasing a system that cannot meet your required tolerances will quickly make the investment useless.
How Is the Scanner Accuracy Specification Calculated?
When comparing 3D scanner specifications, look closely at how the manufacturer established the accuracy number.
What was measured? What size measurement volume was used? Was the measurement two-dimensional or three-dimensional? Was a full volumetric calibration performed? Does scanner accuracy change as the measurement volume increases?
These questions are especially important when scanning larger parts. A small local measurement may produce an impressive accuracy specification, but the total accumulated error across a much larger object could be different. You should understand exactly what the published specification represents.
Test 3D Scanner Accuracy Under Real-World Conditions
Whenever possible, test the scanner using real parts and real operating conditions. Do not rely exclusively on a perfect laboratory demonstration.
If you intend to use the scanner on a production floor, test it on the production floor. Operate near your equipment. Use your normal lighting. Scan your actual parts. Test shiny, dark, or challenging surfaces if those materials are part of your normal workload.
Use known measurement artifacts or parts with established dimensions and compare the results. This will provide a much more realistic understanding of the scanner’s performance.
Scanner Certifications and Recalibration
You should also investigate the scanner manufacturer’s certifications and quality processes.
Does the company manufacture under an established quality management system? What industry or measurement standards are followed? What calibration documentation is provided? What is the recommended recalibration interval? Where is recalibration performed? How long does the process normally take? What does it cost?
The higher the accuracy of a measurement system, the more important calibration and equipment verification can become. Recalibration downtime should be considered as part of the long-term ownership process.
Accuracy is critical, but the published accuracy number is only the beginning of the discussion.
3D Scanning Speed and Total Workflow Time
Scanning speed is another specification that receives significant attention. Manufacturers frequently advertise:
- Measurements per second
- Points per second
- Scan rate
- Laser line count
- Frame rate
These specifications can be useful, but they do not tell the complete story. The real question is:
How long does it take to go from equipment in the case to usable scan data?
This is the total 3D scanning workflow.
Scanner Setup Time
Start with equipment setup. How long does it take to assemble the scanner? Does the system require a large tripod or base? Does equipment need to be leveled? Does the scanner need to warm up?
Some measurement systems may require substantial warmup periods before achieving their specified performance. If a scanner takes 30, 40, or 50 minutes to stabilize, this time becomes part of the workflow. The impact is especially significant for mobile users who frequently move between projects.
3D Scanner Calibration Time
Next, evaluate calibration. How often does the scanner need to be calibrated? How long does calibration take? Is the process simple? Can a normal operator perform the calibration? Or is the process complicated and sensitive to operator technique?
A five-minute calibration process and a 30-minute process create very different daily workflows.
Targets, Spheres, and Part Preparation
Some 3D scanning systems require additional setup before scanning begins. This may include:
- Adhesive positioning targets
- Magnetic targets
- Reference spheres
- SMR nests
- Photogrammetry targets
- Fixtures
- Scan spray
How long does this preparation take? If targets are required, how many must be applied? Does the part need to be cleaned after scanning? Does it need to be securely fixtured? Can the component move during the scanning process? All of this affects total scanning time.
Actual Data Collection Speed
Once scanning begins, scan rate becomes important. Does the scanner use a single laser line or multiple laser lines? How large is the structured light pattern? How much surface area can be captured in each scan? How quickly can the operator move?
However, once again, these questions should be evaluated using your actual parts. A scanner may collect data extremely quickly from a large flat white object. How does it perform on polished metal? What happens when scanning black surfaces? Does scanning speed decrease dramatically when the part contains high-contrast colors? Does the system require significant adjustment when moving between surfaces?
Actual data collection speed can vary based on the object.
Repositioning the Part or Scanner
Very few components can be completely captured from a single position. In many cases, the part or scanner must be repositioned.
How does the system maintain its position during this process? Do you need to move targets? Does the scanner need to be relocated? Do you have to leapfrog reference equipment around the object? Is a manual software alignment required after each scan? Can the part simply be turned over and scanning continue?
The number of setup changes required to capture a complete 360-degree scan can have a major impact on productivity.
Scan Alignment, Merging, and Post-Processing
Data collection is not the end of the process. Multiple scans may need to be:
- Aligned
- Registered
- Merged
- Cleaned
- Optimized
- Meshed
How automated is this process? How much operator interaction is required? Does the software process the data while you scan? How long does final mesh generation take?
When comparing scanner speed, evaluate the complete workflow from the moment the equipment is turned on until a finished, usable scan file is available. A scanner with the highest advertised points-per-second specification is not necessarily the fastest system in actual production.
Service, Training, and Technical Support
Service and support are often overlooked when companies buy a 3D scanner. Unfortunately, some companies discover the importance of technical support only after a problem occurs.
A professional 3D scanning system is more than a piece of hardware. It normally includes scanning equipment, software, calibration processes, computers, and an application workflow. The quality of the service organization supporting the equipment can have a major impact on the system’s long-term value.
Local 3D Scanner Support
One of the first questions to ask is whether local support is available. Can a qualified technician visit your facility? Does the support organization understand your industry? Can they work directly with your parts and applications? Or is all support provided remotely by a general help desk?
Remote support can be extremely effective for many software problems. However, there are situations where having an experienced application engineer physically look at the scanner, part, and work environment can be extremely valuable.
Application-Specific 3D Scanner Training
Training should also be evaluated carefully. Some companies purchase a sophisticated scanner and send operators to a generic five-day training class. The course may cover dozens of features and applications that have nothing to do with the company’s actual work.
An alternative is application-specific training. An instructor may be able to come directly to your facility and train operators using your scanner, your software, and your actual parts.
A company performing reverse engineering has different training requirements than a company performing production GD&T inspection. Training should ideally be focused on the applications that will generate value for the organization.
Ongoing Software and Firmware Support
Ask what happens after the initial training is complete. Are software updates included? How are firmware updates handled? Does the manufacturer continually improve the scanner? What happens when the operating system on your computer changes? How quickly are software problems addressed?
A 3D scanner may remain in service for many years. The long-term software environment can be just as important as the initial equipment purchase.
Hardware Service and Loaner Equipment
Companies using 3D scanning in production should ask about hardware service. What happens if the scanner fails? Where does it go for repair? How long does service normally take? Is loaner equipment available?
For a company that uses a scanner occasionally, two weeks of downtime may be inconvenient. For a manufacturer that relies on the scanner for daily quality inspection, two weeks of downtime may stop production. The value of responsive service increases dramatically as the scanner becomes more critical to your business.
Do not treat service, support, and training as secondary considerations. They should be part of the scanner selection process from the beginning.
Portability and Ease of Use
Portability and ease of use frequently go hand in hand. Not every company requires a portable 3D scanner. However, even systems that remain within one facility may need to move between departments, machines, assembly areas, or production lines.
Look at the Complete 3D Scanning System
When evaluating portability, consider everything required to operate the system. How large is the scanner? How much does it weigh? How many cases are required? Do you need a heavy tripod? Is a granite table required? Do you need a control unit? How many cables are involved? How long does it take to break the equipment down and set it up again?
A scanner head may appear portable in a brochure photograph, but the complete system may be considerably more complicated.
Using a 3D Scanner on the Shop Floor
Think about how easily the scanner can operate in your normal work environment. Can it be used near manufacturing equipment? How does it respond to vibration? Can it handle dust and dirt? What about temperature changes? Can it be used in humid conditions? Will lighting create problems? Can the scanner operate outdoors or in direct sunlight?
A system intended exclusively for laboratory use may create significant workflow problems when moved onto a production floor.
3D Scanner Software Ease of Use
Ease of use also extends to the software. Can operators quickly learn the scanner interface? Is the scanning workflow intuitive? Does the software clearly show where data is missing? Are scanner settings automatically adjusted? How much technical knowledge is required to produce quality data?
The easier the system is to operate, the larger the potential group of users within your organization. This can have a major impact on return on investment.
Imagine a company purchases a $100,000 measurement system, but only one employee knows how to use it. That individual becomes a bottleneck. Every scanning project must wait for the same person. If that employee is on vacation, unavailable, or leaves the company, the equipment may become significantly less useful.
Now imagine a scanner that can be effectively used by engineers, quality technicians, machinists, and experienced manufacturing personnel after appropriate training. The equipment becomes much more accessible. This can greatly increase utilization.
Match the Scanner to Your Operators
Ease of use should be evaluated based on your workforce. Some applications legitimately require experienced metrologists. A company performing advanced GD&T inspection on critical aerospace components should not simply choose a scanner because it appears easy to use.
However, a reverse engineering department scanning relatively straightforward parts may not need an overly complicated metrology system. Choose technology that matches the skill level of the people who will actually use it.
Overall 3D Scanner Value and Return on Investment
The final consideration is overall value. Price is part of value, but price and value are not the same thing. The initial scanner purchase price is easy to identify. The more important question is:
What value will this system provide to the company over its operating life?
Look Beyond the Initial Scanner Price
A lower-cost scanner is not automatically the least expensive system to own. Consider the entire cost of ownership. This may include:
- Scanner hardware
- Software
- Additional software modules
- Maintenance
- Calibration
- Training
- Computer hardware
- Accessories
- Targets
- Scan spray
- Travel
- Downtime
Some scanner systems require multiple software packages to move from scan data to a finished engineering result. Operators may need to learn several different interfaces. Other solutions may provide a more integrated workflow. Evaluate the complete environment rather than the price of the scanner alone.
How Often Will the 3D Scanner Be Used?
Scanner utilization is a major part of ROI. Will the scanner be used daily? Weekly? Once per month? Could departments other than the original purchaser use the system?
A company may initially purchase a scanner for reverse engineering and later discover applications in:
- Quality inspection
- Tooling verification
- First article inspection
- Production troubleshooting
- Digital documentation
- Wear analysis
- Fixture design
The more problems a scanner can solve, the more valuable it may become.
Balance Accuracy, Resolution, and Data Quality
Overall value also depends on obtaining the correct combination of performance characteristics. A scanner can be highly accurate but extremely slow. Another scanner may collect incredibly dense data but have insufficient accuracy for inspection. A very portable system may lack the measurement volume needed for larger projects.
There are always tradeoffs. The best scanner is generally the one that provides the correct balance for your applications.
Consider Operator Skill and Accessibility
A scanner’s value is also connected to how easily it can be used by your organization. How much training is required? Can several employees operate the system? Is ongoing support available? Will the scanner actually be used, or will it sit in a case because the process is too complicated?
Technology only creates value when people use it.
Can One Scanner Handle Multiple Applications?
Versatility can be a major component of scanner value. Can the system scan both small and medium-sized parts? Can it scan challenging surfaces? Can it be used for both scanning and probing? Can the data support reverse engineering and inspection? Can it work in the lab and on the shop floor?
A versatile system may provide substantially more value than a specialized scanner, particularly for companies with changing project requirements. However, versatility should not be pursued at the expense of critical performance requirements. A scanner that does many things poorly is not a good investment. The goal is to find a system that meets your primary requirements while providing useful flexibility in other applications.
How to Compare 3D Scanners Before You Buy
Once you have identified your requirements, we recommend creating a ranked list of the factors that are most important to your company.
This exercise can be surprisingly difficult. Most customers initially say that everything is important. Accuracy is important. Speed is important. Cost is important. Portability is important. Support is important. Ease of use is important.
The problem is that no scanner will receive a perfect score in every category. You need to establish priorities. Create a list of the five or ten most important characteristics and rank them. For example:
- Accuracy and precision
- Part size range
- Scanning speed
- Ability to scan dark and shiny surfaces
- Portability
- Ease of use
- Reverse engineering capability
- Inspection capability
- Local service and support
- Total cost of ownership
You may rank accuracy and precision as your number one priority. If that is the case, total cost of ownership probably cannot also be the second-highest priority. Extremely high accuracy normally comes at a price.
Perhaps portability is your second priority. Maybe ease of use is third. Another company may have completely different priorities.
A manufacturer might primarily scan large black plastic parts on the shop floor. The company may not require the highest possible metrology accuracy. Instead, the ability to quickly capture dark surfaces in a production environment may be much more important.
Another customer may perform extremely high-accuracy inspection in a controlled laboratory and have experienced metrologists on staff. That company may not care about portability or ease of use.
There is no universal ranking. The important part is forcing your organization to establish priorities. Even if you believe two or three characteristics are equally important, try to put them in order. This creates a much clearer framework when you begin comparing scanners.
Do Not Buy a 3D Scanner Based on a Specification Sheet Alone
3D scanner specifications are important, but they rarely tell the entire story.
- Accuracy specifications need to be understood in context.
- Resolution should not be confused with accuracy.
- Advertised scanning speed does not represent total workflow time.
- Portability should include the complete equipment system.
- Software and operator requirements can have a major impact on actual utilization.
- Service and support can become critical when the scanner becomes part of daily production.
The most effective way to evaluate a 3D scanning system is to clearly define your application, establish your priorities, and test the equipment under conditions that represent your real-world workflow.
Bring your own parts to a demonstration. Use challenging surfaces. Scan the complete component. Evaluate the setup process. Watch the calibration process. Process the data. Perform the inspection or reverse engineering workflow you actually intend to use.
Then ask yourself a simple question:
Can our team realistically use this system to solve our problems every day?
The answer to that question is often more valuable than any single specification on a brochure.
Need Help Selecting the Right 3D Scanner?
EMS3D has extensive experience with professional 3D scanning, reverse engineering, 3D inspection, and metrology applications. We work with companies across a wide range of industries to evaluate their applications, determine measurement requirements, and select 3D scanning technology that fits their actual workflow.
Whether you are considering your first 3D scanner, replacing an older system, expanding your current scanning capabilities, or determining whether purchasing equipment makes more sense than outsourcing 3D scanning services, selecting the right technology starts with understanding your application.
The most expensive 3D scanner is not automatically the best scanner. The scanner with the highest advertised scan rate is not automatically the fastest. The scanner with the densest mesh is not automatically the most accurate.
The best 3D scanner is the system that provides the right combination of accuracy, speed, support, ease of use, portability, and overall value for the work your company actually performs.
