August 2025 Metrology News Magazine
Editors Message:
As manufacturers continue their transformation into fully connected smart factories, one concept stands out as a true enabler of this evolution: the digital twin. Once a futuristic idea, the digital twin has now become an operational reality across a growing range of industries. At its core, the digital twin is a dynamic virtual representation of a physical asset or process, continuously updated with real-world data to optimize performance, reduce downtime, and enhance decision-making.
For metrology, integration with the digital twin represents a profound shift in how quality is assured and manufacturing processes are controlled. Measurement data has always been essential for product verification, but in the context of a digital twin, that data assumes a far broader and more strategic role. Instead of inspection being a discrete event at the end of production, metrology now feeds a continuous digital feedback loop enabling real-time validation, simulation, and process correction.
This integration is transforming inspection departments into central hubs of actionable intelligence. Metrology data, when combined with IoT connectivity, advanced analytics, and AI-driven algorithms, becomes a live input for digital models that mirror every detail of a product’s lifecycle. From initial design through to in-field service, a data-driven approach allows manufacturers to predict quality outcomes, identify root causes of deviation earlier, and implement corrective actions long before defects manifest.
The importance of reliable, high-fidelity data cannot be overstated. A digital twin is only as good as the information it receives. That means the accuracy, traceability, and timeliness of metrology data are mission critical. Whether it’s inline sensors capturing measurements during production, or portable 3D scanners feeding cloud-based quality dashboards, every data point contributes to building a richer and more representative virtual model. For companies embracing this paradigm, metrology becomes not just a verification tool, but a driver of innovation and efficiency.
As we look ahead, the convergence of digital twins and data-driven metrology will define the competitive edge in modern manufacturing. Companies that invest in robust measurement technologies, seamless data integration, and analytics-driven quality strategies will lead the charge toward higher productivity and sustainable growth.
This month featured articles included “The Role of AI in High-Precision 3D Scanning for Inspection”; “Manufacturers Are All In on AI – But What Role in Quality?”; “How Digital Twins Will Influence Quality Control in Next Generation Manufacturing”; “Cognitive Automation Set to Drive Quality in Smart Manufacturing Era” and “‘‘Shift-Left’ Moves Quality Upstream in Manufacturing“.
Access the full library of August Metrology News articles by clicking here.
As usual, I welcome your comments, news, and views – my inbox is always open.
Keith Mills – Publishing Editor
The Role of AI in High-Precision 3D Scanning for Inspection
Industrial inspection is under more pressure than ever. Manufacturers across aerospace, automotive, medical, and energy sectors are expected to deliver flawless products while reducing cycle times and production costs. Traditional inspection methods, though precise, often struggle to keep pace with the speed of modern production lines. High-precision 3D scanning has already revolutionized inspection … read more
Manufacturers Are All In on AI – But What Role in Quality?
The global manufacturing industry is undergoing a profound transformation. Confronted with persistent labor shortages, complex supply chains and rising tariffs, manufacturers are turning to artificial intelligence (AI) and automation not just as tools of convenience, but as essential ingredients for future success. The 2025 ETQ Pulse of Quality in Manufacturing survey … read more
How Digital Twins Will Influence Quality Control in Next Generation Manufacturing
In the era of Industry 4.0, one technology stands out for its transformative potential in precision engineering and manufacturing: the Digital Twin. More than just a sophisticated 3D model, a digital twin is a dynamic, data-rich virtual representation of a physical product, process, or system. It continuously updates and evolves by integrating real-time data from the shop floor … read more
Cognitive Automation Set to Drive Quality in Smart Manufacturing Era
Cognitive automation is emerging as one of the most significant enablers of smart manufacturing. By combining artificial intelligence, machine learning, and computer vision with traditional automation, it goes beyond executing repetitive tasks to make decisions, adapt to changing conditions, and continuously learn from data … read more
The Role of 3D Scanning Technology in Advanced Quality Control Systems
Today’s manufacturing environment demands ever-higher efficiency while maintaining strict product quality standards. The concept of Industry 4.0 addresses these challenges by integrating digital technologies and cyber-physical systems into the production ecosystem. At the heart of this transformation is the implementation of tools that enable real-time data acquisition … read more
Reverse Engineering 2.0: Driving Innovation from Prototype to Production
Reverse engineering has evolved far beyond its early reputation as a way to simply replicate existing parts. In today’s manufacturing, it has become a strategic capability enabling rapid prototyping, streamlined production, product lifecycle extension, and even design innovation. Advancements in metrology, 3D scanning, and software have transformed reverse engineering … read more
‘Shift-Left’ Moves Quality Upstream in Manufacturing
Manufacturers are increasingly embracing a ‘shift-left’ approach, moving verification, validation, and risk mitigation earlier in the product lifecycle. This philosophy, originally born in software engineering, is now becoming a central pillar of Smart Manufacturing. By combining model-based definitions, digital twins, in-line sensing, and AI-powered analytics, companies are creating a continuous feedback loop … read more
Cutting a New Path to Redefine Clay Milling
Invention and innovation are the lifeblood of family-owned and family-run TARUS, the only U.S.-based manufacturer of clay milling machines for vehicle design. In 1984, the Michigan-based company completely changed the automotive industry when it introduced the world to its invention, the Claymill. The TARUS Claymill With full milling and scanning capabilities … read more
Xtreme Manufacturing Improved Quality and Inspection Efficiency with 3D Scanning
Xtreme Manufacturing offers the largest and most comprehensive line of heavy-duty and high-capacity telehandlers. Known for their rugged performance and reliability in the most demanding environments, Xtreme places a strong emphasis on quality in every stage of production. To uphold their commitment to quality when inspecting large weldments … read more
Zebra Technologies AI Leader Advises Companies to Rethink Their Frontline Data for AI
Zebra Technologies Corporation, a leader in digitising and automating frontline workflows, is advising businesses to make better use of their frontline data to maximise the benefits of AI solutions. The helpful advice from Stuart Hubbard, Senior Director of AI and Advanced Development, Zebra Technologies, offers hope following a series of reports … read more
Adaptive MEMS LiDAR Brings Precision to Manufacturing
At the World Robot Conference in Beijing, China Orbbec has unveiled its Pulsar ME450, a breakthrough in 3D LiDAR sensing that redefines how robotics systems perceive their environment. With its ability to dynamically switch scanning patterns and adjust vertical fields of view, the Pulsar ME450 introduces a new class of metrology-grade sensors … read more
Fringe Inspection Brings Layer-Level Metrology to AM
In the rapidly evolving world of additive manufacturing (AM), success is increasingly determined by the ability to monitor, certify, and control every layer of the build process. Rooted firmly in the principles of metrology, Phase3D’s Fringe Inspection is rewriting the rulebook for in-situ process monitoring by enabling layer-by-layer inspection with calibratable measurements … read more
Renishaw Launch Third-Generation Laser Tool Setters
Renishaw will launch its latest NC4+ Blue laser tool setter models at the upcoming EMO Hannover 2025. Featuring third-generation technology, the new F100 and F100-10C models set a new standard for tool setting on CNC machine tools and reflect Renishaw’s commitment to advancing metrology for precision manufacturers. With an optimised system NC4+ Blue F100 models achieve industry-leading repeatability … read more
Bruker Alicona to Launch SensorX at EMO 2025
At this year’s EMO exhibition precision measurement expert Bruker Alicona will debut the SensorX, a newly developed high-precision 3D metrology sensor designed for seamless OEM integration. Bruker Alicona will showcase the SensorX fully embedded within the NaPrep preparation cell from Nagel Technologies GmbH … read more
Inspection System Delivers High-Precision Measurement for Stator Manufacturing
As the automotive industry accelerates toward electrification, the precision and reliability of electric motor components have become central to both performance and competitiveness. At the heart of every electric vehicle lies the stator, a key component that determines efficiency, noise levels, and durability. Manufacturing tolerances in stator production are exceptionally tight … read more
Deep Learning Powers Automated Weld Seam Inspection in Automotive Production
Consistently high quality is an absolute must in automotive production. To ensure that welded connections in body shells meet these standards, DGH Group has developed an application that automatically inspects them and identifies anomalies. The MVTec HALCON machine vision software and the MVTec Deep Learning Tool ensure fast and precise inspection … read more
How Découpe H2O Transformed its Dimensional Control System
The need for dimensional metrology really emerged in 2013-2014, when the company started manufacturing small stamping parts. “The aim was to verify the compliance of parts produced with the customer’s CAD drawings and tolerances. Previously, more conventional tools were sufficient for checking bent parts or simple sheet metal parts” … read more
VICIVISION Expands Metrology Capabilities With Launch of X-360
For more than a decade, VICIVISION has specialized in developing optical measuring systems for turned and cylindrical parts across a wide range of industries. By leveraging non-contact inspection, the company’s solutions significantly reduce measurement times while boosting throughput and yield. VICIVISION systems capture the external profile of cylindrical components … read more
Mitutoyo’s TAG Lens Ushers in the Future of High-Speed Microscopy
Mitutoyo’s TAG Lens, a revolutionary advancement in optical measurement technology, leverages Tunable Acoustic Gradient-index (TAG) lens technology. The state-of-the-art system delivers high-speed, all-in-focus imaging that reshapes what’s possible in dynamic, microscopic inspection and real-time 3D observation. Paradigm Shift in Optical Imaging Traditional optical systems often face a trade-off between speed, focus depth, and resolution … read more
Distance Sensor Tackles Challenging Surfaces with Precision and Speed
SICK has launched the new OD200, a compact laser distance sensor for measuring short ranges that sets new standards in this sensor class with its outstanding stability on highly reflective, dark and irregular surfaces. It delivers high performance and productivity even in complex and demanding applications, such as shiny metal and plastic parts and in poor lighting conditions … read more
Digital-Holographic 3D Sensor for Metal Bipolar Plates Quality Assurance
A digital holographic sensor checks the quality of metal bipolar plates for fuel cells with an accuracy of a few micrometers, enabling complete inline quality control for the first time. The sensor data provides the basis for a digital twin of the entire forming process. The digital twin should help understand the causes of recurring errors … read more
AI-Powered Machines To Redefine the Factory Floor at EMO Hannover 2025
Industrial manufacturing is undergoing a change for the ages. AI is finding its way into machine tools and is not only changing production processes, but also maintenance of machines. AI is becoming the control center for efficient, sustainable and competitive production. In times of skills shortages and competitive pressure, it is far more than just a technological gimmick … read more
Large Capacity OGP Smartscope Multisensor System Launched
Optical Gaging Products has announced SmartScope M130, the newest addition to its next evolution of SmartScope 3D Multisensor Metrology systems. SmartScope M130 ushers in the next generation of enhancements in image accuracy, optics, and throughput in a new large format 3D multisensor video measurement platform. At the core of SmartScope M130 is the patented IntelliCentric-M Optical System … read more
Transforming Automated Optical Inspection With Vision AI
In the relentless pursuit for near-zero defects per million (DPM), many manufacturers are turning to Industrial Vision AI for fully automating their inspection processes. Unlike traditional machine vision that relies on rigid, rule-based systems, Vision AI has the agility to learn, adapt and handle day-to-day variability. Using high-resolution imaging technologies, AI algorithms … read more
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