3D Scanner

Built and Designed Functional Scanner

Goal:
The goal of this project was to design and build a fully functional 3D scanner from scratch by combining mechanical design, electronics, and computational modeling. The scanner used a pan tilt mechanism driven by two servos and an infrared distance sensor to capture depth data from multiple angles and reconstruct objects in MATLAB. The intention was to create a low cost, teachable system that demonstrated end to end integration of hardware, calibration, and software processing.

Challanges:
One of the biggest challenges was achieving stable and accurate depth readings. Small misalignments in the pan tilt mechanism or the IR sensor produced noisy or inconsistent point clouds. To address this, we systematically tested servo ranges, recalibrated the sensor’s exponential distance curve, and iterated the mount geometry until the readings became smooth and repeatable.

Another challenge was designing the scanner for usability and repairability. Every component from the servo brackets to the sensor mount was made modular so parts could be re printed or replaced quickly. Press fit joints, pilot holes, and an open frame design reduced the need for tools, improved access to wiring, and made iteration significantly faster. This repair forward mindset also reduced filament waste and allowed rapid testing without rebuilding the entire system.

A final challenge was synchronizing hardware and software. The Arduino needed to coordinate servo movement with real time voltage readings, while MATLAB handled calibration, data collection, processing, and visualization. Fitting the sensor’s nonlinear voltage distance curve to an exponential model required careful tuning to convert raw voltages into usable spatial data.

Outcome:
The result was a cohesive and fully functional 3D scanner capable of collecting clean, legible point clouds from many angles. Mechanical, electrical, and computational subsystems were integrated into a smooth feedback loop where each physical adjustment could be immediately validated in data. The scanner became not only a working device, but also a clear demonstration of how mechanical prototyping, embedded control, and algorithmic calibration come together to create a complete engineered system.