Imagine loading an irregular block of metal, or a finished curved part, into a single station and walking away with precisely cut samples, no specialized machining expertise required. Scan-to-Sample from Los Alamos National Laboratory makes that possible by weaving 3D scanning, design software and computer-guided cutting into one continuous digital thread, running from the first scan straight through to the finished part. The system captures the true shape of the starting material, however curved or complex, then plans and carries out the cuts on its own, sparing operators the slow, error-prone job of hand-aligning and re-zeroing equipment for every specimen. The payoff is faster turnaround, less wasted material and consistent, repeatable quality, bringing advanced machining within reach of a far wider range of users and parts. How it Works The workflow begins when a scanning device, such as a laser scanner, optical scanner or contact probe, captures the exact geometry of the incoming material or part and produces an accurate digital 3D model. Design software then imports that model, where an operator marks the locations, orientations and sizes of the samples or features wanted, and the software calculates the tool paths needed to reach them. Those tool paths are converted into machine instructions, typically a G-code file, and loaded onto a computer numerical control machine, which secures the material and cuts the specimens by following the programmed paths without manual re-zeroing. After cutting, the finished part can be scanned again and compared against the original model to confirm that every specimen meets the required tolerances. Technical Description At its core, Scan-to-Sample links four cooperating elements: i) a scanning device that records the dimensional, geometric and surface characteristics of the workpiece; ii) an operations device that builds a watertight 3D model and generates the cutting program; iii) a machining apparatus such as a multi-axis CNC mill, turning center, grinder, laser or wire EDM system; and iv) a monitoring apparatus that verifies the outcome. The operations device applies a sample extraction model, which carries the functionality of standard CAD and CAM tools, to the 3D model so as to map sampling locations onto the true contours of the part and to derive the tool paths, cutting tools, spindle speeds, feed rates and fixturing choices suited to the material and its tolerances. Because the pipeline is driven by the scanned geometry rather than by fixed programming, it adapts to each unique part and supports two complementary modes of use. In sampling mode, the system extracts small test specimens from complex, non-linear components such as turbine blades or gear teeth, for mechanical testing and analysis. In fabrication mode, the same approach reads a raw or partially formed blank, billet or bar and produces a finished component from it, giving users an experience similar to the guided interfaces common in additive manufacturing. A closed feedback step compares the machined result against the digital model, allowing the system to flag deviations, take an additional sample or stop safely, which keeps quality consistent across every run. Advantages • Removes the slow, error-prone need to align and re-zero the machine by hand for every sample • Lowers the skill barrier, letting users with little machining experience produce complex parts • Handles irregular and curved stock that is hard to fixture and cut by conventional means • Reduces material waste when many small parts are taken from a single piece • Consolidates scanning, design and machining into one connected workflow • Improves precision, repeatability and sample yield across multiple runs Market Applications • Aerospace and Space Systems (turbine blade sampling, launch and propulsion component fabrication) • Power Generation and Energy (gear and turbine component testing) • Materials Research (mechanical behavior specimens for characterization) • Precision Manufacturing (custom parts from irregular or raw stock) • Automotive (drivetrain and gear inspection) • Quality Assurance and Metrology (dimensional verification and defect analysis) TRL 4 US Patent pending LA-UR-26-29796 LANL Tech Partnerships: Unlock the Innovative Potential Los Alamos National Laboratory offers a wide range of cutting-edge technologies and capabilities that may provide your company with a competitive edge in the market and unlock the innovative potential that can enhance, refine, and revolutionize your products. LANL’s licensing program focuses on moving inventions developed by our researchers to commercial innovations. Patented and patent pending inventions and copyrighted software are available to existing and start-up companies through exclusive and non-exclusive licensing agreements. For specific discussions, please contact licensing@lanl.gov. Note: This is not a call for external services for the development of this technology. https://www.lanl.gov/engage/collaboration/feynman-center/partner-with-us/licensing-technology m.lanl.gov/tech-search
