In today’s highly competitive automotive industry, styling is a major differentiator between brands. Surface scanning is the ideal solution to feed modifications on physical prototypes back into the digital design process.

The goal of the pilot plant is to verify all assembly procedures in order to avoid any problems during series production. This requires a thorough dimensional control of every component, subassembly and finally the fully assembled vehicle against CAD data.

During die and mold manufacturing, detailed measurements of tools and first parts together with CAD comparison are very important. Digital copies of existing dies and molds will considerably reduce the time to repair broken tools.

During die and mold manufacturing, detailed measurements of tools and first parts together with CAD comparison are very important. Digital copies of existing dies and molds will considerably reduce the time to repair broken tools.

In order to respond quickly to changes in customer demand, it is important to reduce the time needed to adapt a production line to a new model to the strict minimum. Robot calibration, on-site fixture checking and flexible AGV guidance systems will contribute a lot to this.

The position and dimensions of features such as holes and slots in automotive sheet metal components are critical. Some of these features serve as reference locations for positioning parts at later stages in the assembly process, while others are used to attach trim components to the body.

Machined surfaces of both engine and transmission components have very strict dimensional and form tolerances in order to guarantee their proper operation, a reduced fuel consumption and a long life time. This requires high-speed, high-accuracy next-to-the-line inspection solutions.

Every automotive component whether it is a suspension part, a wheel rim, a bumper or a plastic air filter box has to meet predefined dimensional specifications. Not meeting these specifications is not an option for a supplier.

The first impression a customer gets about a car’s quality comes from small things like the appearance of the gaps around doors or the effort required to close a door. Checking these before a car leaves the factory can highly improve the car’s image.

Measuring actual wheel and powertrain motion during various driving maneuvers is key for both suspension development and packaging studies. CFD, FE and crash simulation on the other hand rely on measured surface models to improve and validate their models.

Metris offers two dedicated technologies for large volume metrology. The Laser Radar for automated large volume inspection and iGPS for large volume handheld probe measurement.

In addition to the dimensional inspection of individual large scale parts or components Metris provides a unique solution for their positioning and assembly during manufacture through its iGPS technology

As part of its portfolio Metris supplies CMM solutions for high precision and large component inspection within the aerospace industry.

Metris scanners are used to either capture critical known areas for instant analysis, or alternatively to capture complete surface geometry for in depth ‘off-line’ analysis.

iGPS technology can be integrated with 3rd party instruments and devices to dramatically enhance their existing capabilities, applications include e.g laser projection systems and large scael riveting machines.

There is a tendency toward ever-more ambitious targets for energy that is clean and inexhaustible. Using technology for large volume measurement, Laser Radar supports manufacturers of wind turbine blades in producing the blade shape for optimum energy conversion.

Automated inspection, superior accuracy and powerful data processing capabilities are among Laser Radar’s strengths that make the difference.

Oil prices and climate concerns brighten the solar energy outlook. Laser Radar verifies the geometric integrity of parabolic solar mirrors to maximize power generation output and profit. Critical in this regard is the capability to trace incorrect bending and misalignments. Laser Radar is fit for these kind of large-scale inspection tasks because it offers accurate measurement and automatic single-user operation.

The quality of turbine blades in stationary gas turbine power plants is critical. 3D laser scanning and Focus point cloud processing accurately digitize the aerofoil surfaces of the blades made of advanced metal alloy castings as well as their fine alignment notches. Detailed inspection avoids inaccuracies in blade geometry and positioning, which otherwise cause energy conversion efficiency loss and untimely blade failure.

Exterior and interior visualization of rocks, fossils, bones, meteorites and other natural samples enable provide ground-breaking insight into mineral sedimentary deposits and the evolution of animal anatomy. Micro-CT already allowed mineralogists, paleontologists, zoologists, ornithologists and entomologists to reveal remarkable aspects of present and past species that were unknown to date.

Large rock and soil samples are examined through CT to trace voids, inclusions and disturbances. These findings are essential in investigating stability issues in the design and construction phases of large infrastructure, such as buildings, pipelines and offshore platforms.

Academic and industry researchers operate industrial X-ray and CT systems to advance research on carbon-fiber material, aluminum honeycomb structures and composite failure mechanisms. Their work with this enabling imaging equipment also focuses on the latest ceramic, plastic and composite structures – including tissue engineering and living composites.

Metallic materials research digs deeper into the fundamentals of solidification and solid state phase transformations. X-ray and CT inspection help acquire information regarding microstructure formation, and improve the properties of commercial steel grades, super alloys or aluminum alloys. Also beneficial are video measuring systems and microscopes that are suitable for metal manufacturing, automotive manufacturing, metallurgy, grain sizing, cast iron nodularity and flake analysis.

Maintaining premium quality in semiconductor wafer and mask manufacturing depends on advanced optical instruments. Image processing technology and proprietary algorithms detect pattern variations with excellent sensitivity.

Efficient transfer sequence, robotic arm, FOUP opener, and enhanced macro observation functions contribute to high yield rates. In addition, specialized microscopes offer suitable optics and digital imaging to perform similar actions manually.

Quality control is key throughout the different manufacturing steps of electronic devices. iNEXIV is a popular tabletop video measuring system used for surface analysis and the investigation of cracks and other failures. NEXIV systems are ideal for automatic verification of flat panels, shadow masks, etching sheets for lead frames, LCDs, mask patterns, and other larger workpieces. Sophisticated illumination types, advanced auto-focus technology and intelligent search capabilities reconcile high imaging quality and fast measurement. In addition, specialized microscopes offer suitable optics and digital imaging to perform similar actions manually.

With the advent of many newer type components such as (µ)BGA and flip-chip devices, optical inspection is no longer an option as the majority of solder connections to the PCB are hidden from view. Electronics systems offering real-time X-ray allow operators to intuitively navigate the internal structure and verify wire bonds, solder joints and through-layer vias. In automatic mode, these systems validate fine-pitch devices as well as BGAs and CSPs, providing complete confidence that boards are assembled right-first-time.

Complex high-tech plastic parts, such as mobile phone covers, set specific challenges in terms of quality and development cycles. The LC15 laser scanner, applying high point density on a small field of view, accurately digitizes these compact and detailed objects with tight tolerances.

The same laser scanner is used for the inspection of plastic shaver parts that are sometimes metal coated. Inspection is used for both inspection and research purposes. XT H 225 is an X-ray and CT system that takes inspection one step further by running quality checks of the razor heads of (disposable) razor units.

Digital cameras and quality watches featuring compact optics, complex mechanics and sensitive electronics also need verification to make sure specifications are met. Ideal for the job are the industrial XT H 225 or electronics XT V160 inspection systems, both supporting CT and combining stunning imaging with high measuring accuracy.

Individual parts can also be measured using CNC video measuring systems, such as iNEXIV and NEXIV systems, and industrial or measuring microcopes.

For some medical components, such as knee or hip implants and hearing aids, the as-built shape of the component is crucial for fast patient recovery and maximum comfort. By digitizing a patient-specific part using a digital laser scanner, the entire geometry can be evaluated on the basis of graphic color diagrams.

Material researchers are developing bone implants made of titanium foam that offer favorable biocompatibility and superior surface roughness and strength. A number of weeks after implanting these plugs into rabbits, CT investigation visualizes and quantifies the bone ingrowth in the ramified porous implant structure.

In the dental segment, computed tomography (CT) is performed to verify correct positioning and orientation of dentures on prosthesis crafted by dental technicians. Both technologies provide geometric information that allows them to fine tune each individual denture design before it is manufactured and inserted into the patient’s set of teeth.

Small imperfections of medical devices and components can be traced using specialized microscopes. High-contrast digital imaging makes it easy to examine the surface of catheters and surgical blades prototypes. Also the performance of new injection moulding tools can be checked or lower volume quality control checks can be performed through microscopy.

Automated non-contact video automatically takes measurements on larger series of complex medical components at a rate that can keep pace with demanding production schedules. Optimum illumination settings ensure repeatable and reproducible edge detection. Non-contact video measurement can also be used to perform CAD comparison and real-time SPC.

With medical devices failure is not an option. By literally looking inside key components and critical assemblies, X-ray and CT face no limitations as to accessing hard-to-reach spots. Radiography is often used to verify the dimensions of drug delivery systems’ inhaler chamber or dispenser mechanism. Likewise, the connections of a pacemaker can be double checked before surgery starts.

Assembling advanced optics is subjected to tight-tolerance inspection. As the optical path of larger instruments is relatively long, Laser Radar is ideally suited to perform measurements on these systems. In many space-related applications, there is no other sensor capable of meeting the metrology requirements. Laser Radar operates with a graphical software interface supporting both manual and automatic use by a single operator.

As part of an ongoing space telescope program, Laser Radar measures mirror features and large mechanical structures holding sensitive flight hardware without touching the specimens. This metrology system automatically verifies optical component alignment because distance limits can be established for near and far focus by managing the focus of its measurement beam. Thanks to its ability to sample both specular and diffuse material surfaces, Laser Radar can determine mirror alignment directly.

For accurate inspection of smaller parts and assemblies, LK CMMs are deployed and equipped with tactile and laser sensors, such as ad LC60Dx and XC65D.

Alternatively, individual parts can be measured using CNC video measuring systems, such as iNEXIV and NEXIV systems, and industrial industrial or measuring microcopes.

A number of space research organizations opt for LK CMMs for parabolic satellite antenna inspection in support of civil space applications. Typically used are very large gantry-type ceramic CMMs with elevated rails that offer high inspection accuracy and compatibility with tactile and laser sensors, such as ad LC60Dx and XC65D.

Smaller individual parts can also be measured using CNC video measuring systems, such as iNEXIV and NEXIV systems, and industrial industrial or measuring microcopes.

Telecom systems typically contain electronics subsystems. For mission-critical space applications, system failure is not an option. Also in other markets, telecom systems are checked inside-out through X-ray and computer tomography (CT) inspection.

By visualizing connectivity failures in electronic devices and circuit boards, or between both, the XT V 160 electronics inspection system provides detailed insight into what really causes the problem. The ability to literally look inside electronic parts and systems is essential in optimizing electronics design and manufacturing practices.

On the electronics production floor, most inspection work is related to electronic connectivity issues including wire bonds, solder joints and through-layer vias. The XT V 130 inspection system is also capable of tracing more challenging defects. Angled imaging with high magnification quickly highlights shorts in the form of solder dendrites and voids scattered around ball grid array (BGA) connections.

Other metrology systems can be used to inspect features and surfaces of electronic components and assemblies that are visible from the outside. iNEXIV and NEXIV are automated video measuring systems that offer the speed and accuracy to quickly run inspection on electronic cards, devices and connectors.

A research project targeting the automotive industry
aimed at streamlining vehicle pre-production phases by simplifying the geometric body verification process. Nikon Metrology and other involved parties joined forces to develop a new geometric verification method for

vehicle bodies, which builds on a digital inspection process using 3D laser scanning and virtual assembly. This method contrasts with traditional body tuning that involves extensive tactile inspection, physical part conflict analysis and complex verification tooling.

Identifying failure mechanisms in composites is important because damage often remains largely invisible externally until late in the testing process. Research using X-ray and CT technology help gain a better understanding of the failure mechanisms and develop mathematical formulae describing the degrading performance characteristics. Research aims at developing and exploiting in-situ rigs that allow multi-mode stressing to be applied on composite samples – a keen interest of international aerospace companies.

Studying metal corrosion mechanisms that occur in nuclear reactors or chemical plants are the subject of another research project. CT observations provide insight into the development of corrosion pits, stress corrosion cracks and their geometries, to improve system design and deduce mathematical formulae. A key aspect is that pitting corrosion in stainless steel usually initiates through local breakdown of the passive surface film.

A cell populated with two industrial robots is used to study how manufacturing quality can be maximized using iGPS. The affordable combination of off-the-shelf robot and metrology technology forms the basis for this research project. Scientists study this enabling combination to maximize manufacturing quality while realizing favorable economics compared to expensive specialty equipment or manual work. This unique concept will benefit numerous dynamic industrial applications, including handling, assembly, burnishing, deburring, welding and pleating.

A vital aspect of studying natural specimens is the ability to visualize their internal structure. Most investigatory methods available solely capture the outer specimen surface, or require edged and colored sample slices to offer a glimpse of the interior. Micro-CT generates stunning 3D visualizations of the interior structure of fossils, animals, rocks and meteorites. They provide researchers ground-breaking insight into mineral sedimentary deposits and the evolution of animal anatomy. Mineralogists, paleontologists, zoologists, ornithologists and entomologists at the museum have already revealed remarkable aspects of present and past species that were unknown to date.

Material researchers are developing bone implants made of titanium foam that offer favorable biocompatibility and superior surface roughness and strength. A number of weeks after implanting these plugs into rabbits, CT investigation visualizes and quantifies the bone ingrowth in the ramified porous implant structure.