Prototype Inspection Using FreeScan Combo and Control X at the TDK site in Hungary

The production unit of TDK Szombathely Factory, specialized in developing and manufacturing electromagnetic interference (EMI) filters, switched to 3D scanning thanks to FreeDee, our reseller in Hungary. Our vendor enabled them with a FreeScan Combo se they could easily and effectively check the dimensions of their products to meet evolving customer demands.

The trend of "miniaturization" has not bypassed industrial electronic products: increasingly complex products are being designed to fit into smaller and irregularly shaped spaces, posing ever-higher geometric requirements for manufacturers.

About the TDK Szombathely Factory

The TDK site in Szombathely is one of the most significant European electronics development and manufacturing centers within the international TDK group and one of FreeDee's oldest 3D printing partners. The factory's 3D printing needs are supported by a central 3D lab. Recently, the EMI filter development department also expressed a need for optical 3D scanning, leading to the adoption of a FreeScan Combo handheld laser scanner in early 2024. Our local Hungarian partner, FreeDee Kft. spoke with Krisztián Holló, a senior design engineer, about the results of in-house 3D scanning.

FreeScan Combo scanning TDK's components

Challenges in Prototype Inspections

TDK's customers want EMI filters installed in ever-smaller and more complex environments, which increasingly require measurements that are challenging or impossible with traditional methods. Meeting these sophisticated measurement demands posed a challenge for TDK's team in adhering to project deadlines required to secure client projects.

FreeScan Combo handheld 3D laser Scanner and Geomagic Control X Quality Control Software.

The required measurements became feasible, with the necessary time reduced from approximately two weeks with outsourced external partners or 3-4 days with the internal measurement lab to an average of 2-3 hours.

Time Constraints in EMI Filter Development

TDK's primary customers for EMI filters are in the renewable energy sector. These filters are often used in wind turbines, industrial inverters, and vehicle chargers. Order quantities typically range between 100 and 1,000 units, with no two products being identical. TDK offers EMI filters in various sizes, from fist-sized units to table-sized devices weighing hundreds of kilograms.

Customers usually issue tenders for the required EMI filters, specifying tight deadlines—1-2 months—to deliver samples and price quotes. These deadlines include tasks such as documentation preparation, procurement of materials, initial assembly, measurements, and modifications. Speedier submissions often determine the winning bid, and the successful bidder manufactures it.

In recent years, the shrinking installation spaces and increasingly complex customer demands have added to the time pressures faced by prototype developers.

"While it was sufficient to ensure the overall dimensions of industrial EMI filters, customers now also request positional tolerances, flatness, and other complex dimensions. Meeting these advanced precision requirements was very difficult or impossible with our previous traditional methods," said Krisztián Holló, Senior Design Engineer at TDK Hungary Components Ltd.

Adopting Advanced Measurement Solutions

The more complex measurement demands could no longer be met using simple measuring tools available in the development department. Collaborating with the central measurement lab was the only internal option, but their priority was validating finished products. Consequently, scheduling and inspecting prototypes in the lab could take 3-4 days. To address these sophisticated measurement needs quickly, the team turned to high-precision optical 3D scanning, initially outsourcing these tasks to FreeDee. However, outsourcing sometimes resulted in lead times of up to two weeks, prompting the decision to bring the competency in-house.

"The best option for us is to solve these issues within the department. A two-week lead time is far too long when our customers set 1-2-month deadlines. To meet these and win projects, we needed to bring 3D scanning in-house," Holló explained.

Component's Mesh display on our Control X software

Choosing the Right 3D Scanner

Building on an established partnership with FreeDee, which had supplied 3D printing equipment to TDK since 2018, the EMI filter developers initially outsourced 3D scanning tasks to them. These outsourced scans confirmed that 3D scanned models enabled easy verification of geometric requirements previously considered challenging.

The decision to purchase an in-house 3D scanner gained urgency when a major customer required a 3D scanned model for a prototype. The customer used the scanned model to integrate it into their own 3D design, ensuring compatibility with physical installation processes.

"Before purchasing, we tested and evaluated several 3D scanners and ultimately chose the FreeScan Combo laser scanner due to its outstanding value for money. The on-site demonstration and the scans performed by FreeDee played a significant role in our decision" , said Holló.

Workflow with FreeScan Combo and Geomagic Control X

Since its launch, the FreeScan Combo has become one of SHINING 3D's most popular handheld 3D scanners, designed specifically for metrological scanning. It offers rapid data capture with 26-50 laser lines and 20-micron accuracy. Its compact size ensures convenient and quick operation, while various scanning modes support efficient workflows for both rapid and detailed digitization.

Analysis using SHINING 3D's Control X software: The scanned data is analyzed and compared to CAD models using Geomagic Control X, one of the most well-known quality control software tools. It offers simple workflows, automated reporting, and easy parameterization of complex measurement tasks.

Control X software showing TDK scanned component

Results of In-House 3D Scanning at TDK

Following scanner demonstrations and evaluations, the FreeScan Combo was implemented at TDK on March 11, 2024.

"Thanks to the 3D scanner, what used to take up to two weeks with outsourcing can now be completed in-house in 2-3 hours," said Holló.

The scanner captures complete surface data, enabling future checks even if physical prototypes are unavailable. TDK has already leveraged this capability for product refinements. Although the scanning process initially seemed simple, the team experienced a learning curve due to the diverse nature of product samples.

Krisztián Holló, Senior Design Engineer, TDK Hungary Components Kft.

"Whenever we encountered difficulties, FreeDee provided prompt assistance. For 3D scanner selection, having a competent partner is critical to maximize the technology's potential quickly," Holló emphasized.