FCH - Scanning and routing a human face – SCOPES-DF
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Lesson Details

Subjects *
Computer Programming, Technology
Age Ranges *
11-14, 14-18, All ages,
Fab Tools *
CNC Router, Computers,
Author
Julia Teeninga
Additional Contributors
NURIA ROBLES

Author

Julia Teeninga

Summary

The “Scanning a Human Face and CNC Machining a 3D Model” activity is part of the FabConnectHer project, which encourages young women to explore creativity and technology through STEAM (science, technology, engineering, art, and maths). In this lesson, students learn how to scan a human face, edit the scan, convert it into an STL file, and use a CNC router to machine a 3D model.

 

The activity introduces students to 3D scanning and CAD software, showing how digital files can be prepared and transformed into physical objects. It also gives students insight into CNC machining, from setting up the machine to generating toolpaths and exporting G-code.

 

This lesson is suitable for middle school, high school, and college students. By the end, students will understand how 3D scanning, CAD, and CNC machining are connected, gain confidence in using new technologies, and see how digital design can be turned into real-world objects.

What You'll Need

Materials Needed:

  • 3D scanner (e.g., Sense, Structure Sensor, Artec Eva, or similar)
  • Computer with 3D scanning software (e.g., Meshmixer, Blender, or similar)
  • CAD software (e.g., Fusion 360, Tinkercad, Aspire or similar)
  • CNC router
  • Material for CNC machining (plywood or Blue styrofoam, machinable wax or something       thicker than 40mm )
  • Safety equipment (goggles, ear protection, dust mask)
  • USB drive or other data transfer methods
  • Safety rules & tips CNC router!

 

Learning Objectives

  • Learn how to set up and use a 3D scanner to capture a human face.
  • Import, clean, and edit 3D scans using software to improve model quality.
  • Convert a 3D scan into an STL file for use in CNC machining.
  • Use CAD software to prepare the STL file, set dimensions, scale, and generate toolpaths.
  • Understand how to export G-code correctly for a CNC router.
  • Learn how to safely set up and operate a CNC router.
  • Observe and understand the process of machining a 3D model from start to finish.
  • Build confidence in exploring new technologies like 3D scanning, CAD, and CNC machining.

 

Reflection

This activity gives students a chance to see how digital design can be turned into a physical object. By scanning a face, editing it on the computer, and then machining it with a CNC router, they learn the full process from idea to product. It helps students understand how technologies like 3D scanning, CAD, and CNC machining connect and are used in real-world industries.

 

The project also builds problem-solving and critical thinking skills, since students must clean up scans, prepare files, and follow safety rules. Watching their digital model become a real object builds confidence and excitement about what is possible with modern technology. In the end, students see that advanced tools can be learned step by step and used creatively to bring ideas to life.

The Instructions

Setting Up the 3D Scanner (15 minutes)

Students learn how to set up and calibrate the 3D scanner, understanding why accurate calibration is important for good results.

  • Demonstrate how to set up and calibrate the 3D scanner.
  • Explain the importance of proper calibration for accurate scans.

 

Scanning a Human Face (30 minutes)

Students practise scanning a human face by positioning the subject and scanner correctly, capturing all angles, and splitting the scan into halves.

  • Choose a volunteer for the face scan.
  • Show how to position the scanner and subject for optimal results.
  • Guide students through the process of scanning the face, capturing all necessary angles.
  • Split the face in half.

 

Editing and Converting the Scan to an STL File (1 hour)

Students import their face scan into 3D software, clean and edit it by removing errors and smoothing surfaces, then convert the finished model into an STL file ready for CNC machining.

Step 1: Importing the Scan (15 minutes)

  • Demonstrate how to import the scan into 3D editing software.
  • Explain the basic interface and tools of the software being used.

 

Step 2: Cleaning Up the Scan (20 minutes)

  • Show how to clean up the scan by removing any unwanted parts or noise.
  • Teach students how to fill holes and smooth surfaces to improve the quality of the 3D model.
  • Split the face in half and lay flat.

Step 3: Converting to STL (25 minutes)

  • Guide students through the process of converting the cleaned-up scan to an STL file.
  • Explain the importance of exporting the file in the correct format for CNC machining.

 

Preparing the STL File for CNC Machining (1 hour)

Students import their STL file into CAD software, set the correct orientation, scale, and supports for machining, generate toolpaths, and export the model as G-code for the CNC router.

Step 1: Importing the STL into CAD Software (15 minutes)

  • Demonstrate how to import the STL file into CAD software.
  • Explain the basic tools and interface of the CAD software.

 

Step 2: Preparing the Model for CNC Machining (30 minutes)

  • Show how to orient the model for optimal machining.
  • Lay the (half) face looking up.
  • Explain how to set the dimensions, scale, and create supports/bridges* if necessary. (*small parts of wood to keep the model in place)
  • Teach students how to generate toolpaths for the CNC router.

 

Step 3: Exporting the G-code (15 minutes)

  • Guide students through the process of exporting the prepared model as G-code.
  • Explain the importance of correct settings for the material and CNC router being used.

 

CNC Machining a 3D Model (1 hour)

Students learn how to safely set up the CNC router, load their G-code, and observe the machining process as the router carves their 3D model.

Step 1: Setting Up the CNC Router (15 minutes)

  • Demonstrate how to set up the CNC router, including securing the material and loading the G-code.
  • Emphasize safety procedures and the use of safety equipment.

 

Step 2: Machining the Model (30 minutes)

  • Show how to start the CNC machining process and monitor its progress.
  • Allow students to observe the machining process and discuss the steps involved.

 

Finishing Touches and Evaluation (15 minutes)

Students remove their finished model from the CNC router, smooth any rough edges, and reflect on the project by discussing results, challenges, and how the skills learned could be used in future work.

  • Demonstrate how to remove the finished model from the CNC router and clean up any rough edges.
  • Discuss the outcome of the project and any challenges faced during the process.
  • Encourage students to reflect on what they learned and how they could apply these skills in future projects.

 

Extension activities

Students can extend their learning by scanning different objects, editing STL files with custom designs, and testing CNC machining on various materials, while being assessed on their technical skills, participation, and problem-solving.

  • Experiment with scanning different objects and creating STL files for CNC machining.
  • Modify the STL file to add personalized features or designs before machining.
  • Explore different materials and settings for CNC machining to see how they affect the final product.
  • Using plywood to CNC route will give a nice design in layers

 

Assessment:

  • Students will be assessed on their ability to scan a face, clean and convert the scan to an STL file, prepare the model for CNC machining, and successfully machine the model.
  • Participation in discussions and troubleshooting sessions will also be considered.

 

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