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Morgan has been producing high quality hand-crafted motor vehicles since 1909 and at its Malvern Hills facility in Worcestershire since 1913. Today it produces its modern take on a British classic with an approach that embodies Morgan’s heritage but embraces new technologies.
The traditional Morgan 4/4 is the longest running production vehicle in the world and is manufactured by a series of hand crafted and super-plastically formed aluminum panels. This is a high end process reserved for advanced aerospace
applications and limited series exotic sports cars.
The evolution at Morgan is truly in the engineering of the cars. Technology Manager Graham Chapman has been instrumental in deploying new technology to build a greater understanding of the existing processes and in developing new methodolo- gies for future builds.
Part of that modernisation plan was to ‘digitise’ certain key characterises of their chassis and body structures.
  Verisurf Software, from GTMA supplier Metrology UK, was selected as the metrol- ogy software product of choice along with fellow member Hexagon’s Romer articulat- ing scanning arm.
The software/hardware combination pro- vides Morgan with a user-friendly digital route from hand built components assem- blies to the CAD engineering team. The engineers can then produce up-to-date CAD designs of traditional legacy car platforms. This provides great insight into the current build process and gives a planning method for repeatability.
Global standards and approval requirements impose great challenges on the design of new vehicles, so Verisurf provides the dimensional controls that are a must for any modern car manufacturer.
Verisurf’s scanning and reverse engineering functionality is also deployed for prototype design and build. Scanning clay scale mod- els from the designers to capture the key dimensions and styling cues to start the engineering process.
Tom Morris-CAD/Technology Engineering said: “Verisurf and the Romer arm has been a huge asset to the engineer- ing team here at Morgan. It provides us with array of functionality to achieve our goals.
The Romer arm is light in weight but has a rugged carbon fibre construction and with Verisurf software there is no project we can not achieve.”
Graham Chapman said: “We were looking for a solution that was easy to use but pro- vides the high end functionality to deliver quality scans and inspection data that can be engineered to meet our exacting stan- dards here at Morgan Cars. Morgan is a tra- dional methods car builder but that does not mean we reject new technologies to achieve our goals of a British Classic.”
Verisurf software has been deployed in some of the most prestigious and well established companies world-wide: From Boeing to tra- ditional companies like Morgan Cars.
It has unique CAD based architecture with on-board solid/surface modelling and uses the latest ‘push/pull’ modelling functionality which breaks new ground in the metrology sector.
Images courtesy Morgan Cars and Metrology UK, whose Verisurf Software has been selected as the metrology product of choice by the iconic motor vehicle producer.
As a modular based product it allows users to select their desired configuration to achieve solutions to their applications and budgets. Ease of Use has been a priority for Verisurf since the beginning in 1993 and its functionality goes beyond standard metrolo- gy software as it is a ‘one stop’ application for engineering measurement needs.
Key features include Verisurf CAD which reads all native CAD file formats including IGES, STEP, CATIA, Unigraphics/NX, Pro-E, SolidWorks, SolidEdge, AutoCAD, AutoDesk Inventor, and others. This flexibility means you can easily work with any CAD model - solid, surface or wireframe.
It includes the proprietary Verisurf Device Interface (VDI). This powerful interface con- nects and controls virtually all measuring devices, including stationary and portable CMMs, laser trackers and scanners, and many others. gory/verisurf/

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