Case Study: U.S. Army’s Aberdeen Test Center achieves ten-fold reduction in measurement uncertainty with 3D Systems' 3D scanning and Geomagic Control

3D Scanning and Inspection by 3D Systems Geomagic Software Validates U.S. Army's Body Armor Tests

The U.S. Army’s Aberdeen Test Center (ATC) tests soft and hard body armor to ensure it protects soldiers, but its traditional caliper-based method captured only a single point, was time-sensitive due to conditioned clay used as a torso surrogate, and introduced human decision and uncertainty into critical backface-deformation measurements. ATC needed a faster, repeatable, and defensible measurement process to give vendors reliable test results and, most importantly, to better protect troops.

ATC implemented a FaroArm Quantum 3D scanner and Geomagic Control inspection software with custom automation to perform pre- and post-shot full-surface scans, process data rapidly (3–5 minute scans, ~1 minute processing), and generate automated reports. The new workflow removed manual judgment, archived complete 3D models, and reduced measurement uncertainty tenfold—from 2.0 mm to 0.2 mm—making test results more accurate, repeatable, and actionable for improving armor and soldier safety.

U.S. Army’s Aberdeen Test Center

Craig Miser

Chief of the Applied Science Test Division