Good work, Khalid! I too built an automatic scanner using David-Scanner, which made it much faster and had better results.
I struggled with mesh aligning as well. I found two free software tools that helped quite a bit:
1) Meshlab: Has global alignment and mesh merging tools that can handle lots of scans. It aligns very well, but crashes a little too often. I use David-Scanner to roughly align the meshes, and output to Meshlab to make a much-much tighter alignment using a global averaging alignment. David-Scanner doesn't align meshes nearly as well.
2) Scanalyze: This was a free tool, but very difficult to get set up and working properly. It does have a lot of power for aligning meshes, especially lots of them (24+).
I ended up purchasing a license of Leios Mesh, which was very expensive, but the lowest cost mesh/alignment/merging tool that I liked to work with. It makes aligning and merging very easy, and gets excellent results. Polyworks, RapidForm and Geomagic also work very well, but they are incredibly expensive.
-Dan  |