THE CHALLENGE
In industries such as additive manufacturing, aerospace, and medical device production urgently need fast and reliable surface measurement tools capable of capturing features at the micron level, yet current commercial 3D scanning systems cannot deliver this performance. Most scanners are limited to about 50 micrometers in resolution, which is too coarse to detect the tiny melt pool wrinkles or surface defects that directly impact product quality and reliability. While advanced methods like interferometry offer extreme accuracy, they are far too slow and cumbersome for real-time use on the factory floor, leaving manufacturers with a costly gap between precision and practicality. Calibration tools further compound the problem, as they are not designed for validating measurements at this scale and are highly sensitive to noise from reflections and lens distortions, making it even harder to trust the results. This shortfall creates a critical business problem because without accurate, rapid, and practical metrology solutions, companies risk higher scrap rates, increased costs, and compromised product performance in highly competitive markets where precision is everything.
OUR SOLUTION
We offer an ultra-high resolution structured light 3D scanner that delivers spatial resolution down to 2 micrometers, far surpassing the limits of existing commercial systems. By combining high-resolution cameras and lenses with a novel calibration method using custom ceramic targets with precision PVD patterns, the system achieves accuracy validated at 3.5 to 5 micrometers with an average error of only 0.05 micrometers. Specialized techniques such as polarized lighting, controlled overexposure, and advanced software algorithms ensure noise reduction and sub-pixel accuracy, enabling rapid, non-contact measurement of millions of data points within seconds. This breakthrough allows manufacturers to detect the smallest defects in real time at a fraction of the cost of traditional high-end systems, unlocking a practical and affordable solution for industries like additive manufacturing, aerospace, and medical devices where precision, speed, and reliability are critical for business success.
Figure: Example of a reconstruction of a three-dimensional scan performed using the structured light three-dimensional scanner.
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