The tolerance was estimated to be within +-0.125 inches or better for individual scans, but it may be worse for some areas depending on how well the merged scans are aligned. The accuracy of the scan seemed reasonable. So ultimately, the scan was not particularly helpful for the detailed design of the cage other than serving as a rough visual fit check. I was unable to find a way to select any of the points in the point cloud inside the scan. I had to manually eyeball the position of the scan to locate it in the model. However, since the 3D scan had no datum planes or points I could select, the model was difficult to use. Importing the model and 3D scan into Autodesk Fusion360 had a much better result. Since the original roll cage model was made in SolidWorks, I tried importing the 3D Scan into SolidWorks, but the scan shows up as a massive point cloud with no shading that is hard to view. I tried ReconstructMe and Skanect, but I ended up preferring KScan3D since it seemed to merge individual scans better. There are several free 3D Scanning software packages available that work with the Xbox Kinect. One of the things I wanted to try before building a roll cage for my BMW was scanning the interior of the car to test fit the roll cage CAD model.
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