Surface_Profile_Digital_Scanner_SOW-FBO.pdf

UNITED STATES MINT

United States Mint Solicitation# USM-HQ-15-0005 Surface Profile Digital Scanner Statement of Work

B ac kg ro un d

S ca n Pr oc es si ng

R ef er en ce

T ec h O ve rv ie w

Table of Contents

Table of Content ………………………………………………………………………….2 Purpose…………………………………………………………………………………….3 Background………………………………………………………………………………..4 Terminology………………………………………………………………………………12 Technical Overview………………………………………………………………………14 Scan Processing…………………………………………………………………………...20 Statement of Work (S.O.W.)……………………………………………………………...22 Requirements……………………………………………………………………………...24 Reference………………………………………………………………………………….27

Purpose

This document will provide the groundwork for evaluation, benchmarking, and purchase of non-contact scanning technology for the purpose of capturing 3D artwork data from

United States Mint coins and coin die tooling ac kg ro un d

United States Mint Surface Profile Scanning

Automated Scanning & STL File Output Statement of Work

Background

C.1 BACKGROUND:

The US Mint is the largest mint in the world and produces all of the circulating coins for the United States as well as a large number of extremely valuable collectable coins. Coin designs are sculpted in BAS relief.

This is a very specific form of sculpture where extremely detailed portraits & landscapes are reduced to very low levels of relief for coin-ability, while maintaining the essence of a sculpture. All US Mint coin designs are sculpted on a concave and convex spherical surface (known as the field). Even though coins look flat, they are not.

The United States Mint has four manufacturing facilities: Philadelphia (PA), Denver (CO), San Francisco (CA), and West Point (NY). Philadelphia serves as the main manufacturing site and facilitates all of the coin and metallic design related activities as well as the manufacture of all master tooling. The Philadelphia location also serves as the main R&D facility for the US Mint.

Over the past five years, the US Mint has invested heavily in the research, development and implementation of numerous digital design and manufacturing technologies to produce all of its coin die tooling. One of these design technologies utilizes non-contact scanning technology to gather complex 3D surface data from coins and coining dies ranging in size from 0.635” to 3” in diameter; with the most common size being 1.033” in diameter. Once scanned, resultant mesh data (STL) is brought into our digital sculpting software (FreeForm, Zbrush, Mudbox, etc.) for further refinements and processing

The US Mint is looking for an automated – turnkey process where coin dies, and struck coins can be loaded onto a table/platform and scanned with a high level of accuracy and the resultant 3D data processed via supplied software to: remove stray/errant points, smooth detail, fill holes, apply decimation, flip normals, combine or repair meshes, develop cross-sections, perform dimensional analysis, compare struck coins to actual coin die tooling and master digital models, develop mesh to mesh deviation plots, develop presentation graphics, reports, etc. Once purchased, the system will be installed at the US Mint location in Philadelphia, Pennsylvania.

C.1.1 Terminology and Technology Overview

See Attachment J.1

C.2 REQUIREMENT

Contractor shall develop, deliver & implement an automated, turnkey solution to accurately scan United States Mint steel coin dies, and gold, silver and clad coins as well as provide software capable of processing all scan data to deliver production ready STL meshes.

C.2.1 System Requirements

1. The solution must solely utilize non-contact scanning technology.

2. System must have adequate range of motion to facilitate scanning coin dies & actual coins with diameters between 0.635 – 3.000 inches and heights of relief ranging from 0.005 – 0.150 inches.

3. Scanner must facilitate automated positioning of the work-piece as needed via X/Y linear table and/or rotary stage so as to capture all artwork, lettering, and field detail with no voids or missing scan data.

4. Low frequency floor vibration condition exists throughout facility where scanner equipment will be located. Use of anti-vibration equipment may be necessary.

5. In production, all scanning functions must be handled via macro(s) or custom automation interface(s) with minimal human interaction required other than loading/unloading, part setup, etc. of the work piece.

C.2.2 Vibration

Low frequency floor vibration condition exists throughout facility where scanner will be located. Use of a vibration isolation table is recommended as part of the vendor’s proposal.

Note: current scanner uses the following anti-vibration table:

TMC ( Technical Manufacturing Corporation ) Model Table No. 63M-533 Table top dimensions 30” x 36” Micro-g Gimbal Piston, Vibration Isolation Lab Table.

Vertical natural frequency 1 – 1.9 Hz, depending on input.

Horizontal natural frequency 1.2 – 2.2 Hz depending on input.

MaxDamp isolators with “stiffer feel” while maintaining high performance

C.3 INSTALLATION

The Contractor shall install all equipment purchased. (more details)

1. Vendor shall provide delivery schedule for proposed hardware & software including installation, set-up, and training

2. The Contractor shall supply the requisite technical personnel to install & test all equipment purchased.

C.4 ACCEPTANCE TESTING

United States Mint final acceptance will be contingent on the contractor successfully testing all equipment prior to installation.

C.4.1 Benchmark Testing

The Contractor shall perform evaluation (benchmark) tests at the Contractor’s facility. The Contractor will be required to scan & process two (2) coin dies, & two (2) coins selected by the United States Mint (see reference pages at the end of this SOW)

C.4.2 User Acceptance Testing

The United States Mint will perform final user acceptance testing at the United States Mint facility in Philadelphia.

1. Testing will include complete processing and CNC milling of test coin die tooling to determine suitability of equipment & software for our design and manufacturing processes.

C.5 TRAINING

The Contractor shall provide one week of training for two operators. (more details)

C.6 SPARE PARTS

The Contractor shall provide a price list recommended spare parts.

C.7 TECHNICAL SUPPORT

1. The Contractor shall provide technical support capabilities covering: hardware & software malfunctions, diagnostics, etc. and provide pricing structure for yearly technical support for the life of the equipment.

2. The Contractor shall also provide pricing for an annual preventative maintenance program for the life of the equipment.

3. The Contractor shall provide specifics on out-of-warranty repair costs including travel fees.

4. The Contractor shall provide pricing per day for five (5) days of on-site applications support per year for the life of the equipment. *Days may be non-contiguous.

NOTE: All personnel visiting the US Mint will need to submit to, and pass a background clearance check prior to gaining access to the

C.8 DOCUMENTATION

Contractor shall provide complete documentation to the United States Mint covering: specifications, operational use, failure diagnostics, copy of any custom automation source code.

C.9 EVALUATION DEMONSTRATION

With its proposal, vendor shall submit the results of an evaluation demonstration. The evaluation will consist of three separate phases: scanning (including automated part positioning & scan data collection), scan processing (including scan data filtering, clean-up, and STL mesh output), and production testing (including loading STL mesh into US Mint digital sculpting software and subsequent CNC milling). The Contractor will only be responsible for performing the scanning & scan processing phases. The vendor shall provide all services and resources required to facilitate the scanning and subsequent processing of (1) one US Mint supplied dollar coin die and one (1) one standard quarter dollar coin. This may require custom hardware, software, testing, debugging, installation and/or modifications to current system(s).

Due to the unique nature of the US Mint’s manufacturing processes coupled with the security involved in the manufacture of US currency; production coin dies cannot be sent to any Contractor for testing. Instead, Martha Washington test designs will be sent for initial evaluation.

The US Mint will supply the following items to the Contractor for evaluation and processing. All will be accompanied by US Mint Form #601 (Temporary Asset Transfer).

Included will be:

* (1) Martha Washington die in one dollar ($1) denomination

* (1) US Quarter coin (25¢) - uncirculated

* The Martha Washington coin die and coin will be on loan to the Contractor for the express purpose of evaluating their technology and developing a proposal in response to this Statement of Work.

Upon completion of evaluation and/or proposal, all items must be returned to the United States Mint along with the accompanying #601 document. An instruction sheet pertaining to filling out the #601 Form will also be sent with the test items.

C.9.1 Scanning

Vendors must scan three different sized coin dies up to 1.033” in diameter x 2.045 height (reference p. 12) and one US Quarter coin (25¢). Use of surface treatments (sprays, powders, etc.) on dies or coins will not be permitted.

X/Y Linear Table and/or Rotary Axis – Supply hardware/software and automate the movement of linear table and/or rotary axis to position coin die or coin for scanning.

C.9.2 Scan processing

Vendors must process coin die and coin scans using vendor supplied software to yield production ready STL meshes. Vendors must deliver raw scan data (as scanned) as well as fully processed scan data to the US Mint for evaluation. Any processing applied to raw scan data must be fully documented and a written report must accompany the corresponding STL files when delivered to the United States Mint for testing.

Tessellation cordial deviation tolerance (coin die & coin) = 2.54 nm

C.9.3 Production testing

The United States Mint will load resultant STL meshes into FreeForm and other design software to determine suitability for the United States Mint’s digital sculpting process. The United States Mint will process final data with CAM software implemented at the United States Mint followed by CNC milling to evaluate tessellation quality and suitability for the United States Mint’s digital manufacturing process.

*Current digital design process uses an input STL file size of 300MB

C.9.4 Output

Format of resultant output files must be in industry standard STL format (binary).

*US Mint firewall constraints require STL data to be supplied to the US Mint on DVD.

The US Mint will only accept UPS ground/air & FedEx priority shipments.

Ship to information:

United States Mint – Engraving Division 151 N. Independence Mall East Philadelphia, PA 19106-1886

Attn: Eric Custer: 215-408-0250

C.10 Submission Requirements

The Contractor shall provide the following technical information in their proposal.

1. Scanning:

Output file format – Industry standard binary STL, and ASCII point cloud X/Y table & rotary axis movement specifics (include specs on accuracy, repeatability, etc.)

2. Scan Processing:

Provide specifications on software features & capabilities.

3. Processing Time:

Execution time required for complete scanning of: a) $1 coin die; b) $.25 coin Execution time required for scan processing to final STL file for a, b, & c above.

ac kg ro un d

Obverse Reverse

FIGURE 1

2008 Silver Eagle

The United States Mint has four manufacturing facilities: Philadelphia (PA), Denver (CO), San Francisco (CA), and West Point (NY). Philadelphia serves as the main manufacturing site and facilitates all of the coin and medallic design related activities as well as the manufacture of all master tooling. The Philadelphia location also serves as the main R&D facility for the United States Mint.

Over the past five years, the United States Mint has invested heavily in the research, development and implementation of numerous digital design and manufacturing technologies to produce all of its coin die tooling. One of these design technologies utilizes non-contact scanning technology to gather complex 3D surface data from coins and coining dies ranging in size from 0.635” to 3” in diameter; with the most common size being 1.033” in diameter. Once scanned, resultant mesh data (STL) is brought into our digital sculpting software (FreeForm, Zbrush, Mudbox, etc.) for further refinements and processing

The United States Mint is looking for an automated – turnkey process where coin dies, and struck coins can be loaded onto a table/platform and scanned with a high level of accuracy and the resultant 3D data processed via supplied software to: remove stray/errant points, smooth detail, fill holes, apply decimation, flip normals, combine or repair meshes, develop cross-sections, perform dimensional analysis, compare struck coins to actual coin die tooling and master digital models, develop mesh to mesh deviation plots, develop presentation graphics, reports, etc.

Once purchased, the system will be installed at the United States Mint location in Philadelphia, Pennsylvania.

Surface Profile Digital Scanner SOW Attachment

Terminology

Coin die actual size

Enlarged image of Martha Washington coin die

Terminology

US Mint coin die tooling- shown in approximate scale to plaster model

Struck coin inverse of work die ec h O ve rv

Technical Overview

Image of Martha Washington non-sense test model depicting the level of modeling complexity

FIGURE 3

FIGURE 4

FIGURE 5

Planar slice along Section A-A showing the concave spherical surface (field) on which the artwork & lettering are modeled.

A

A ec h O ve rv

FIELD

FIGURE 6

Section A-A through the Martha Washington design showing the field to artwork & lettering relationship.

For clarity, the Z-scale is exaggerated slightly to better demonstrate the concave spherical surface (field).

Cross section through the raised letter “R” in MARTHA

Cross section through the raised letter “G” in WASHINGTON

Cross section through the incused letter “A” in VIRGINIA

Figures 7, 8 & 9 show a vertical planed intersecting with typical letter and field geometry.

FIGURE 7

FIGURE 8

FIGURE 9

FIGURE 10

FIGURE 11

Figures 10 and 11 show close-up areas of the artwork – for reference

FIGURE 13

Image of Martha Washington coin die to be scanned NOTE: Only the top face with the coin detail will be scanned

FIGURE 14

1.033

DIAMETER

S ca n Pr oc es

Scan Processing

FIGURE 15

FIGURE 16

Raw scan data

Filtered scan data

Enlarged view of filtered scan data

Enlarged view of raw scan data ca n Pr oc es

Scan Processing

Scan Processing – Preferred comprehensive scan processing capabilities, with sophisticated interactive software tools to:

- facilitate complete part or area scanning

- remove stray/errant points

- apply smoothing filters based on surface tolerance, curvature rate, etc.

- fill holes (automatic & manual)

- position scan data for flatness, concentricity, rotation angle (clocking), alignment

- decimation (reduce) resultant STL file size based on chordal deviation, tolerance, minimum/maximum triangle size, etc.

- select triangle type options (regularized, polygon, etc)

- flip normals

- combine and stitch meshes

- evaluate & repair meshes

- develop user defined cross-sections

- compare scans (analysis - curvature, distance, deviation, etc)

- apply dimensioning & documentation (presentation graphics, etc)

- quickly process large data sets

- automate repetitive operator tasks through programs/macros.

.O .W

Statement of Work (S.O.W.)

Develop & implement an automated, turnkey solution to accurately scan United States Mint steel coin dies, and gold, silver and clad coins as well as provide software capable of processing all scan data to deliver production ready STL meshes. Only non-contact scanning technology will be considered. System must have adequate range of motion to facilitate scanning coin dies & actual coins with diameters between 0.635

– 3.000 inches and heights of relief ranging from 0.005 – 0.150 inches. Scanner will need to facilitate automated positioning of the work-piece as needed via X/Y linear table and/or rotary stage so as to capture all artwork, lettering, and field detail with no voids or missing scan data. *Low frequency floor vibration condition exists throughout facility where scanner equipment will be located. Use of anti-vibration equipment may be necessary. In production, all scanning functions to be handled via macro(s) or custom automation interface(s) with minimal human interaction required other than loading/unloading, part setup, etc. of the work piece.

The evaluation will consist of three separate phases: scanning (including automated part positioning & scan data collection), scan processing (including scan data filtering, clean-up, and STL mesh output), and production testing (including loading STL mesh into United States Mint digital sculpting software and subsequent CNC milling). The Contractor will only be responsible for the scanning & scan processing phases.

Scanning – scan three different sized coin dies up to 1.033” in diameter x 2.045 height (reference p. 12) and one US Quarter coin (25¢). Use of surface treatments (sprays, powders, etc.) on dies or coins will not be permitted.

X/Y Linear Table and/or Rotary Axis – Supply hardware/software and automate the movement of linear table and/or rotary axis to position coin die or coin for scanning.

Scan processing – process coin die and coin scans using Contractor supplied software to yield production ready STL meshes. Deliver raw scan data (as scanned) as well as fully processed scan data to the United States Mint for evaluation. Any processing applied to raw scan data will be fully documented and a written report must accompany the corresponding STL files when delivered to the United States Mint for testing.

Tessellation cordial deviation tolerance (coin die & coin) = 2.54 nm

Production testing – resultant STL meshes will be loaded into FreeForm and other design software to determine suitability for the United States Mint’s digital sculpting process. Final data will be processed with CAM software implemented at the United States Mint followed by CNC milling to evaluate tessellation quality and suitability for the United States Mint’s digital manufacturing process.

*Current digital design process uses an input STL file size of 300MB

.W

Scope of Work

The Contractor shall provide all services and resources required to facilitate the scanning and subsequent processing of (1) one United States Mint supplied dollar coin die and one (1) one standard quarter dollar coin.

This may require custom hardware, software, testing, debugging, installation and/or modifications to current system(s).

Format of resultant output files must be in industry standard STL format (binary).

*United States Mint firewall constraints require STL data to be supplied to the United States Mint on DVD.

Due to the unique nature of the United States Mint’s manufacturing processes coupled with the security involved in the manufacture of US currency; production coin dies cannot be sent to any Contractor for testing. Instead, Martha Washington test designs will be sent for initial evaluation.

The United States Mint will supply the following items to the Contractor for evaluation and processing. All will be accompanied by United States Mint Form #601 (Temporary Asset Transfer).

Included will be:

* (1) Martha Washington die in one dollar ($1) denomination

* (1) US Quarter coin (25¢) - uncirculated

* The Martha Washington coin die and coin will be on loan to the Contractor for the express purpose of evaluating their technology and developing a proposal in response to this Statement of Work.

Upon completion of evaluation and/or proposal, all items must be returned to the United States Mint along with the accompanying #601 document. An instruction sheet pertaining to filling out the #601 Form will also be sent with the test items.

The United States Mint will only accept UPS ground/air & FedEx priority shipments.

Ship to information:

United States Mint – Engraving Division 151 N. Independence Mall East Philadelphia, PA 19106-1886

.W

Requirements

The Contractor shall provide the following technical information in their proposal.

Scanning:

Output file format – Industry standard binary STL, and ASCII point cloud X/Y table & rotary axis movement specifics (include specs on accuracy, repeatability, etc.)

Scan Processing:

Provide specifications on software features & capabilities.

Processing Time:

Execution time required for complete scanning of: a) $1 coin die; b) $.25 coin Execution time required for scan processing to final STL file for a, b, & c above.

Vibration:

Low frequency floor vibration condition exists throughout facility where scanner will be located. Use of a vibration isolation table is recommended. Note: current scanner uses the following anti-vibration table:

TMC ( Technical Manufacturing Corporation ) Model Table No. 63M-533 Table top dimensions 30” x 36” Micro-g Gimbal Piston, Vibration Isolation Lab Table.

Vertical natural frequency 1 – 1.9 Hz, depending on input.

Horizontal natural frequency 1.2 – 2.2 Hz depending on input.

MaxDamp isolators with “stiffer feel” while maintaining high performance

Installation:

The Contractor shall supply the requisite technical personnel to install & test all equipment purchased.

Acceptance Testing:

Evaluation (benchmark) tests will be performed at the Contractor’s facility. Final acceptance will be determined by scanning & processing two (2) coin dies, & two (2) coins of the United States Mint’s choosing (see reference pages at the end of this SOW) at the United States Mint facility in Philadelphia.

Said testing will include complete processing and CNC milling of test coin die tooling to determine suitability of equipment & software for our design and manufacturing processes.

.W

Training:

Training will be performed on first shift 8:00 – 4:30 for five continuous days. The training will be for operations and maintenance of the scanning system during startup and scanning operations. The Contractor shall supply the operations and maintenance manuals and any other applicable training materials to be used during the in-house training sessions.

Spare Parts:

The Contractor shall supply a list of recommended spare parts along with pricing.

Technical Support:

The Contractor shall detail their technical support capabilities covering: hardware & software malfunctions, diagnostics, etc. and provide pricing structure for yearly technical support for the life of the equipment..

Additionally, provide pricing for an annual preventative maintenance program for the life of the equipment.

Applications Support:

The Contractor shall provide pricing per day for five (5) days of on-site applications support per year for the life of the equipment. *Days may be non-contiguous.

Repairs:

Provide specifics on out-of-warranty repair costs including travel fees.

* NOTE: All personnel visiting the United States Mint will need to submit to, and pass a *

* background clearance check prior to gaining access to the facility *

Documentation:

Provide complete documentation to the United States Mint covering: specifications, operational use, failure diagnostics, copy of any custom automation source code.

Delivery:

Provide delivery schedule for proposed hardware & software including installation, set-up, and training.

Contacts

All technical inquiries should be directed to the following individuals:

TBD at Award