A METHOD AND SYSTEM FOR BUILDING A DATA MODEL OF A PHYSICAL PART IN A DATA FORMAT USEFUL FOR REPRODUCTION OF THE PART

Method and system are provided for building a data model of a physical part in a data format useful for reproduction of the part. The system preferably includes a Moir+E,acu e+EE interferometry system including a camera mounted on a portable coordinate measuring system (CMM) to obtain high density data scans in the form of 3-D point data from different positions and orientations of the interferometry system relative to the part. The CMM provides position data to enable an engineering workstation to convert the data scans obtained in multiple local coordinate systems into a single global coordinate system. The engineering workstation then integrates the data scans in the global coordinate system and joins the point data to form a polygonal structure corresponding to multiple continuous surfaces of the physical part. From this data, a tool path can be generated to cut a reproduction of the part or a mold for molding the reproduction. Alternatively, a stereo-lithography or FDM file can be generated for use in a fused deposition molding (FDM) system to form a mold layer-by-layer. Such a mold can then be adapted for use in a system to vacuum cast the reproduction.