Optical scanning system and method

1 . An optical scanning attachment coupled to a digitizing arm for use in a three-dimensional (3D) scan of a surface of a partially closed volume, the optical scanning attachment comprising:

at least one laser operable to generate a laser light at a frequency;

at least one optical element operable to receive the laser light and generate a light pattern, wherein the at least one optical element is configured to provide the light pattern on the surface of the partially closed volume, and wherein an image of the light pattern on the surface of the partially closed volume comprises surface contours;

at least one camera comprising a lens and configured to receive the image of the light pattern on the surface of the partially closed volume; and

an elongated member having a proximal and a distal end, wherein the proximal end is positioned closer to the digitizing arm as compared to the distal end, wherein the at least one laser is positioned so that external laser light emanates adjacent the distal end of the elongated member, and wherein the at least one camera is positioned adjacent to the distal end of the elongated member.

2 . The optical scanning attachment of claim 1 , wherein at least a portion of the lens is positioned outside the elongated member.

3 . The optical scanning attachment of claim 1 , wherein a portion of the lens positioned outside the elongated member is co-planar to the elongated member.

4 . The optical scanning attachment of claim 1 , wherein a portion of the lens positioned outside the elongated member is non-planar to the elongated member.

5 . The optical scanning attachment of claim 1 , wherein at least a portion of the at least one optical element is positioned outside the elongated member.

6 . The optical scanning attachment of claim 1 , wherein the image of the light pattern on the surface of the partially closed volume is transmitted, via a fiber optic cable, to the digitizing arm for processing, and wherein the light pattern is conical or flat.

7 . The optical scanning attachment of claim 1 , wherein the lens is at least one of a fisheye lens or a wide angle lens, and wherein the at least one optical element is at least one of a conical mirror or prism.

8 . The optical scanning attachment of claim 1 , further comprising:

an interface positioned at the proximal end and configured to fixedly couple to the digitizing arm.

9 . The optical scanning attachment of claim 1 , wherein the laser light is generated by a plurality of lasers, wherein the laser light is aggregate of the plurality of lasers.

10 . The optical scanning attachment of claim 1 , wherein the at least one camera comprises at least one of a plurality of cameras or a plurality of lenses.

11 . The optical scanning attachment of claim 10 , wherein the plurality of cameras comprises at least four cameras each configured to receive a different image of the light pattern on the surface of the partially closed volume.

12 . The optical scanning attachment of claim 1 , wherein the light pattern on the surface of the partially closed volume is a conical projection, and wherein accuracy of the at least one camera is based on at least one or more of attributes selected from the group consisting of a megapixel size of the at least one camera, a size of a camera field of view of the at least one camera, an aspect ratio of the at least one camera, a rated accuracy of the at least one camera, a camera field of view to corners of the at least one camera, an arm tolerance of the digitizing arm, and a type of the at least one camera.

13 . The optical scanning attachment of claim 1 , further comprising:

a contact sphere fixedly coupled to the distal end of the elongated member.

14 . The optical scanning attachment of claim 1 , wherein the at least one optical element is a flat mirror and wherein the lens is a line lens.

15 . The optical scanning attachment of claim 1 , wherein the at least one camera is positioned off-axis to the distal end, and wherein the partially closed volume is at least one of a casting with a core, a welded sheet metal part or assembly, a riveted assembly, a composite structure, or a tube structure.

16 . An optical scanning system comprising:

a digitizing arm comprising a processing circuit for processing images;

a digitizing arm interface fixedly coupled to the digitizing arm;

an optical attachment coupled, via the digitizing arm interface, to the digitizing arm for use in a three-dimensional (3D) scan of a surface of a partially closed volume, the optical scanning attachment comprising:

at least one laser operable to generate a laser light at a frequency;

at least one optical element operable to receive the laser light and create a light pattern, wherein the at least one optical element is configured to provide the light pattern on the surface of the partially closed volume, and wherein an image of the light pattern on the surface of the partially closed volume comprises surface contours;

at least one camera comprising a lens and configured to receive the image of the light pattern on the surface of the partially closed volume, and wherein a portion of the lens positioned outside the elongated member is co-planar to the elongated member; and

an elongated member having a proximal and a distal end, wherein the proximal end is positioned closer to the digitizing arm as compared to the distal end, wherein the at least one laser is positioned so that external laser light emanates adjacent the distal end of the elongated member, and wherein the at least one camera is positioned adjacent to the distal end of the elongated member.

17 . The optical scanning system of claim 16 , wherein at least a portion of the at least one optical element is positioned outside the elongated member, and wherein the image of the light pattern on the surface of the partially closed volume is transmitted, via a fiber optic cable, to the digitizing arm for processing, and wherein the light pattern is conical or flat.