AR Inspection Tool Cuts Production Error Rates by up to 90%
Visometry, the specialist for industrial augmented reality, has released Twyn 2.5, the latest version of its iPad-based AR inspection tool that uses CAD data for fast, visual quality checks. The update delivers expanded capabilities through a significantly enhanced Assisted Deviation Detection (ADD) engine and introduces new usability and IT-integration features designed for both individual inspectors and large enterprise deployments.
The result: inspection times reduced by up to 80% and production error rates cut by as much as 90%, according to feedback from quality managers using Twyn in demanding industrial environments.
Twyn has steadily expanded from its early adoption in automotive, agricultural machinery, toolmaking, and welded component inspection to new sectors, including shipbuilding, rolling stock production, and aerospace, where rapid, mobile, and highly reliable product verification is increasingly mission-critical.
“Across industries, quality teams face the same challenge: the need for fast, mobile checks combined with rising pressure on time, efficiency, and cost,” says Florian Schmitt, Product Manager for Twyn at Visometry. “Conventional fixed or complex metrology systems can’t always meet those needs alone. Twyn closes that gap.”
Visometry’s development roadmap is guided closely by industry needs, with customer input gathered through regularly organized user meetings.
Assisted Deviation Detection
Among the most substantial upgrades in Twyn 2.5 is the next-generation Assisted Deviation Detection (ADD) engine. The system can now reliably evaluate extremely small features such as weld spots, assessing whether they meet specifications or require rework. Inspectors can also move closer than 30 cm to capture details—overcoming a previous limitation.
The enhanced ADD is especially relevant to automotive body-in-white inspection and aerospace component verification, where millimetric precision is essential.
“This makes ADD ideal for body construction and the precise inspection of small components,” says Schmitt.
The improved ADD continues to excel at comparing real-world edges to CAD-defined nominal geometry and instantly indicating deviations—or confirming a correct assembly with clear green-light status signalling.
Supporting Production Workflows and Distributed Manufacturing
Twyn 2.5 also aligns with a growing trend in manufacturing: distributed production of sub-assemblies, often located far from final assembly plants, and sometimes in facilities without specialized inspection teams or equipment.
A rapid Twyn check can prevent defective modules from reaching a paint shop, entering final assembly, or being transported over long, expensive supply routes. Conversely, it can eliminate unnecessary precise measurements when no defect is present—particularly valuable for large components where each additional processing step incurs significant cost.
Twyn’s intuitive interface keeps training requirements low, allowing operators to quickly adopt the tool and integrate it into standard quality procedures such as error prevention and the principle of ‘check before you measure’.
Beyond shop-floor functionality, Twyn 2.5 also introduces improvements designed specifically for IT departments and global manufacturing enterprises. As more organizations deploy long-term Twyn licenses across multiple sites, Visometry has added enterprise interfaces that streamline rollout and integration.
“We’re enabling IT teams to deploy Twyn across locations and seamlessly interlink inspection workflows, CAD data, and product revisions,” explains Schmitt.
This backbone supports increasingly traceable, scalable, and data-connected quality processes – a must-have as manufacturers accelerate digitalization and seek competitive advantages through smarter quality control ecosystems.
Ready for the Next Wave of Smart Manufacturing
With its combination of advanced deviation detection, simplified workflows, and enterprise-level integration, Twyn 2.5 positions itself as a key enabler of next-generation inspection processes. Its ability to replace or complement fixed metrology stations with a highly portable, CAD-driven AR tool makes it especially suited to an era of flexible production, distributed supply chains, and rapid product iteration.
As industries continue to demand speed without compromising precision, the new Twyn release demonstrates how augmented reality can help close critical gaps in quality assurance—reducing errors, cutting inspection time, and delivering actionable insights wherever they are needed on the factory floor.
For more information: www.visometry.com
