Incorrect alignment after generating merged model of two point clouds

Scanner: MetroX
Software: Revo Scan 5.6.9 MetroX, Revo Metro 5.8.6
Platform: Win10

Issue: When merging point clouds, their alignment looks good in “Preview the Alignment”, but when I click “Generate Model” it looks completely different. Sometimes skewed only a couple of mm, sometimes the two parts are floating independently. This is the first time I had something like that happen and I’ve scanned +70 elements and the results were rather pleasant.
I tried Revo Metro, same issue.

Examples:

Google Drive link to the project with the flat part above:

Hi @mIsHo

I am even surprised that you got any merged result with this featureless scans .

Try to use manual points , but it is going to be tricky , too little features , too symmetrical , you may just scan another angle vertically and use it as a base for merging the other parts to it , I guess the only solution here.

Thanks for the reply, but it still doesn’t answer my question. Why does it look good before generating merged model, but distorted after. If it couldn’t connect the two point clouds, it would tell me via a popup. I also had this problem when merging scans, that had cloud1, cloud2 and a cloud3, that is inbetween. And I know that the order of merging is important, so I merged cloud1, cloud3, cloud2. Still didn’t help…

I know that I can merge manually, but it usually is the last resort, when I get that “overlap less than 10%” popup

Hi @mIsHo

The feature mode needs unique features to be merged and there is no other way around . Every other software will get confused by it , it also don’t have enough overlapped points , preview is not actual merging either, it is just preview and I am aware that sometimes it shows like it would be merged just fine, but in reality the final processing can’t find the needed features to do the job accurately.

If you use feature mode you need to follow the proper workflow for successful merge , no matter what software you use for it.

Regarding the merge order , it is not scan 1-2-3
What is important that you choice the best complete scan as number 1 and the worse for number 3 , regardless which you scanned first or last.

Please ignore the preview , you can’t actually relay on it unless you used at least manual point placement .