SHINING 3D FreeScan Trak ProW – wireless metrology 3D scanner with VPG

Key features

• 0.023 mm accuracy for industrial metrology, quality control and reverse engineering.
• Up to 5,500,000 points/s for capturing large surfaces and complex geometry.
• Tracking up to 8.6 m, with a single-position tracking volume up to 206.7 m³.
• FreeTrak W dynamically tracks TE25W without manually placed markers on the part in the standard Trak workflow.
• Three laser configurations: 50 lines for high-speed scanning, 7 parallel lines for detail and 1 line for deep holes and pockets.
• Wireless and wired operation, integrated Video Photogrammetry (VPG) and compatibility with optional FreeProbe accessories.

Industrial 3D metrology across a large working area

SHINING 3D FreeScan Trak ProW combines dynamic optical tracking and laser 3D scanning for medium, large and very large objects. The system pairs a FreeTrak W optical tracker with a TE25W handheld laser scanner. The tracker monitors the scanner's position in real time, allowing the operator to move around the part without relying on sequential recognition of markers attached to its surface.

This is useful for vehicle bodies, production equipment, large castings, machine components, moulds, tooling and structures where applying many adhesive markers is undesirable or inefficient. Scanning can begin after positioning, connecting and checking the system, reducing surface preparation.

A maximum tracking distance of 8.6 m and single-position tracking volume of 206.7 m³ reduce the need to relocate the tracker during large-object measurement. Fewer moves simplify maintaining a common coordinate system and planning the inspection.

FreeScan Trak ProW combines rapid data capture, metrology-grade accuracy and freedom of movement. It can be used in a measurement room or around production equipment, assembled structures and objects that are impractical to move to a stationary measuring machine.

Accuracy, volumetric accuracy and laser modes

The stated accuracy is 0.023 mm. For large parts, local accuracy alone is insufficient: volumetric accuracy describes measurement performance across the whole working volume. The specified values are 0.046 mm at 15.6 m³, 0.063 mm at 45 m³, 0.088 mm at 76 m³ and 0.127 mm at 128 m³. Evaluate these against the size and tolerances of the intended project.

Integrated Video Photogrammetry (VPG) supports expanded measurement volumes with volumetric accuracy of 0.044 + 0.012 mm/m. The video photogrammetry workflow uses a calibration reference to establish and check spatial referencing without requiring coded markers.

TE25W offers three laser configurations. Use 50 laser lines to cover large surfaces quickly, 7 parallel lines for finer local geometry, and 1 laser line for deep holes, narrow channels and pockets. The single-line mode is complemented by deep-hole optimisation.

Point spacing is adjustable from 0.01 to 10 mm. The smallest value is not automatically appropriate for every project: excessive density on a large smooth surface increases file size and processing load without a matching benefit. Apply higher density locally to small radii, edges, holes and functional features.

Speed, wireless operation and data control

Capture speeds up to 5,500,000 points/s support productive scanning of vehicle panels, bodywork, large fixtures, castings and industrial structures. This helps prevent data collection from becoming a bottleneck when a large area must be covered.

The system supports wireless operation with mobile power, reducing cable restrictions as the operator moves around the object. A wired mode with an optical connection is available when a physical communication link is preferred.

FreeScan Trak Software provides scanning-mode, surface-type, brightness and data-density controls, plus live coverage feedback. Intelligent Resolution can increase mesh density automatically in highly curved regions, balancing broad flat areas with fine local geometry. AI Feature Recognition identifies circular holes, rectangular holes and slots, supporting inspection of functional features on sheet-metal parts.

1. Position FreeTrak W securely with a clear view of the planned measurement area.
2. Connect the components and check their status.
3. Calibrate before first use or when a new check is required.
4. Select the laser mode and suitable point spacing.
5. Adjust brightness and surface settings.
6. Scan while monitoring coverage and tracking in real time.
7. Clean and optimise the data, then generate a mesh.
8. Export or transfer the result for inspection or reverse engineering.

Software, file formats and metrology integration

FreeScan Trak Software covers capture and measurement-data preparation, including editing, removal of unwanted data, mesh optimisation, smoothing, simplification and hole filling. Prepare the data for its next use instead of exporting an unnecessarily heavy model.

Export an optimised point cloud as ASC or a mesh as STL, PLY, OBJ or 3MF. Global markers can also use P3, ASC and TXT. These formats support downstream CAD, inspection and reverse-engineering workflows.

The system integrates with SHINING3D Inspect, EXModel Pro, BlueStar Mapping, PolyWorks, Geomagic Control X and Geomagic Design X. Scanned geometry can be compared with nominal CAD, analysed for deviations, reconstructed as surfaces or used to build a new design model.

An optional FreeProbe adds contact measurements for points and features that are difficult to capture optically. This is useful in hidden areas, deep features or tasks that require a direct point measurement rather than a complete mesh.

The recommended workstation configuration is Windows 11 Professional 22H2 64-bit, Intel Core i7-13700H or better, NVIDIA GeForce RTX 4060 Laptop GPU or better, at least 8 GB VRAM, 64 GB dual-channel DDR5 RAM and USB 3.0. RAM and GPU performance directly affect how comfortably large datasets can be processed.

Design and application examples

The handheld TE25W weighs 1.4 kg, while the FreeTrak W weighs 10.6 kg and acts as the stationary spatial reference. The tracker's integrated display provides operating-status information at the measurement location.

• Automotive: inspection of body panels, body-in-white structures, battery trays and large sheet-metal components with less preparation.
• Reverse engineering: digitisation of parts without an available or current CAD model.
• Tooling: comparison of moulds, dies, fixtures and production tools with nominal geometry.
• Heavy engineering: capture of large castings, welded structures and machine components on the production floor.
• Energy: digitisation of large components that are impractical to move to stationary measuring equipment.
• Hard-to-reach features: optical scanning combined with optional FreeProbe contact measurements.

Limitations, calibration and good practice

Optical tracking requires visibility between FreeTrak W and TE25W. Plan the tracker position so critical surfaces can be reached without prolonged loss of sight. For complex structures, tracker placement belongs in measurement planning.

Dark and reflective surfaces require the appropriate software mode and brightness. Transparent or highly mirror-like materials remain challenging and should be tested on a representative area. Where the workflow allows it, temporary matting with a dedicated scanning spray can improve optical contrast.

Avoid strong direct sunlight on the measurement area outdoors. Intense ambient light can increase optical noise and reduce coverage. Shade or controlled lighting is preferable for metrology tasks.

Calibration is required at initial setup. The software records the latest procedure and issues reminders after an extended interval. Recalibrate before critical inspection when the measurement environment changes, after transporting the system or when deviations are suspected.

Technical specifications