Zeiss high-precision measurement technology: Optical, tactile and CT solutions for industrial applications
Zeiss will be presenting advanced measurement technology for precise quality control in industrial production at the trade fair. The solutions on show make it possible to optically scan components, compare them with CAD data and precisely analyze deviations. A particular highlight is the ATOS scanner, which uses high-resolution images to generate a point cloud, which is then converted into a complete 3D mesh file. This process enables the high-precision capture of complex components, including injection-molded plastic parts, metal components or high-precision production parts made from other materials.
In addition to optical solutions, the portfolio also includes tactile measuring devices, computed tomography (CT) systems and microscopic analysis methods that enable non-destructive inspection. The spectrum ranges from manual inspection systems for random sample analyses to fully automated inline solutions that guarantee 100% inspection in the production line.
ATOS Scanner: Optical measuring systems for high-precision quality control
The ATOS scanner is based on an optical triangulation process that enables very detailed digital recording of components. By using high-resolution cameras and special projection methods, millions of points on the component surface are captured. This data is merged in real time to form a dense 3D mesh, which is saved as an STL file.
It is then compared with CAD target models in order to precisely determine dimensional deviations, deformations or manufacturing tolerances. The visual representation is provided by a color-coded deviation analysis in which critical areas are marked in red. This allows faulty components to be identified immediately and corrective measures to be initiated in a targeted manner. The optical measuring method is particularly suitable for free-form surfaces that are difficult to detect using tactile measuring methods. Thanks to the special triple scan principle, even areas that are difficult to access, such as deep holes or undercuts, can be measured, which is often not possible with conventional optical measurement technology.
Tactile measuring devices and CT scanning: in-depth analyses for complex components
In addition to optical methods, Zeiss offers a wide range of tactile measuring devices that are used for high-precision contact testing of form and position tolerances. This technology is particularly suitable for metallic components where maximum dimensional accuracy is required.
In addition, computer tomography (CT) measurement technology is used to analyze internal structures non-destructively. Using high-resolution X-ray images, even the finest defects such as blowholes, cracks or material inclusions can be made visible. This method is particularly in demand in aerospace, medical technology and additive manufacturing (3D printing). A major advantage of the Zeiss solutions lies in the standardized software platform: measurement data from optical, tactile and CT systems can be evaluated in one environment with the Zeiss Inspect software, which reduces training costs and gives companies flexible analysis options.
Automated and flexible measurement technology for series production and quality assurance
The measuring solutions from Zeiss are not only designed for use in the measuring room, but can also be integrated into production lines. For this purpose, the company offers automated inline measurement solutions that enable seamless quality control in series production.
Standardized and individually adaptable measuring cells are used to analyse components directly after production. Integration into existing production processes takes place via standardized interfaces to ERP, QM and production control systems (MES). This enables complete traceability of the measurement results and a direct connection to production databases. The Zeiss Solutions department also develops customized automation solutions for individual customer requirements. These range from semi-automatic test benches to fully integrated robotic measuring cells that automatically feed, record and evaluate components.
From small components to large structures: flexible application options
The measurement technology from Zeiss covers an extremely wide range of applications - from the inspection of the smallest precision parts to the measurement of large structures. While the smallest entry-level systems are available from as little as €25,000, the ATOS Q scanners range from €150,000 to €170,000, depending on the configuration. Zeiss develops customized high-end solutions for large-scale industrial projects, such as the automated measurement of 20-metre-long ship engines. Thanks to their modular design, the systems can be flexibly expanded and adapted to specific manufacturing processes. From manual inspection solutions for suppliers to fully automated 3D scans in series production - Zeiss offers the right solution for every quality control process.
Conclusion: High-precision measurement solutions for Industry 4.0
Zeiss is setting new standards in industrial quality assurance with its optical, tactile and CT-based measuring systems. By combining the latest 3D scanning technologies, high-precision sensors and intuitive software, companies can raise their production quality to a new level. Zeiss systems ensure reliable and reproducible quality control, especially in industries with the highest demands on dimensional accuracy - such as the automotive industry, aerospace, medical technology or additive manufacturing. Thanks to the automated measurement solutions, inspection processes can be designed efficiently and errors in production can be detected at an early stage. With Zeiss, companies not only receive the most precise measurement technology, but also a flexible, future-proof solution that can be optimally integrated into existing production processes.
