TEST, SAFETY, SYSTEMS
MOTION METROLOGY IN Siobhan Doyle explores how
advanced 3D metrology devices are improving vehicle quality and safety
The Presto system enhances adaptability in manufacturing P
recision is everything in the fast-paced world of automotive manufacturing, where even the smallest deviation
can cause costly malfunctions or compromise safety. At the heart of this precision lies metrology – the science of measurement. From ensuring fl awless alignment
of engine components to verifying the structural integrity of safety features, metrology plays a pivotal role in maintaining quality. As demand for electric vehicles (EVs) rises, the need for accuracy becomes even more important. By providing actionable insights,
metrology drives eff iciency, enhances decision-making, and ensures that precision is embedded at every stage of the manufacturing process. “Automation and adaptability are
key here because EV production is constantly evolving,” says Ignazio Dentici, VP of global e-mobility and automotive at Hexagon’s Manufacturing Intelligence division. “Metrology tools allow manufacturers to adjust scanning procedures through software rather than reconfi guring the hardware, saving additional time and eff ort.”
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THE IMPORTANCE OF ACCURACY For decades, the study of metrology – which includes the development, application, and improvement of measurement standards and techniques – was viewed as a necessary but cumbersome hurdle, reserved for fi nal quality checks. Any errors meant costly reworks or scrapped parts. Today, advanced metrology solutions are fl ipping this narrative. With advanced technologies, metrology no longer slows production. Instead, it off ers real-time data that bridges the gap between design and execution. Among the developers of this
technology is Hexagon’s Manufacturing Intelligence (MI) division, which engineers advanced metrology tools like 3D laser scanners and coordinate measuring machines. These devices help automotive manufacturers maintain tight tolerances, ensuring precise part alignment and fi t.
IMPROVING SAFETY Metrology plays a huge role in improving safety by enhancing reliability. This applies to structural integrity as well as the chemical and electrical components within EVs. For
instance, using volumetric scanning and CT technology, car manufacturers can inspect areas previously invisible, like the porosity of weld seams or overlaps in battery electrodes. These insights prevent potential issues like thermal events or mechanical failures. “With electrifi cation, safety
challenges extend beyond mechanical reliability to include electrical functionality,” Dentici adds. “Electrical failures can sometimes pose greater risks than mechanical ones, so ensuring the precision and quality of EV components is critical. Metrology combined with AI and digital twins helps us guarantee that parts are manufactured to exact specifi cations, ensuring both performance and safety.”
A SEAMLESS DESIGN PROCESS 3D metrology scanners enhance automotive design by capturing highly accurate, detailed measurements of components. This precision enables engineers to identify design fl aws early, refi ne prototypes faster, and ensure optimal alignment. By improving accuracy, 3D scanners streamline the design process, reduce development time, and boost overall
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