Breaking New Ground With 3D Scanners In Metal Forging and Forming Sector
For 185 years, Bharat Forge CDP GmbH has been a hallmark of expertise and craftsmanship in metal forging and forming. Based in Germany, the company is known worldwide as an innovative leader and a trusted supplier to a wide range of industries, including the automotive, rail transportation, and mechanical engineering sectors. As a manufacturer of chassis components for passenger cars and commercial vehicles, Bharat Forge holds itself to the highest standards of safety, precision, and innovation.
Outgrowing Traditional 3D Measurement Methods
With its long-standing tradition of being ahead of the curve in metal forming and forging technologies, the company decided it needed to invest in new solutions to proactively meet customer demands.
“As a supplier of safety-critical components, we must measure parts multiple times throughout the production process to ensure the utmost quality and comply with project specifications,” explained Florian Heimbeck, Inspection Planner / Metrology at Bharat ForgeCDP Gmb. “We simply cannot afford inaccuracies or delays in our 3D measurement processes.”
Over the years, the company’s conventional tactile 3D measuring system became more of a problem. While reliable, it required specialized operators with years of training. Even then, each complex component took up to two hours to measure—time that was not viable in a fast-paced, competitive landscape. In addition, the outdated system was limited in its ability to capture intricate part geometries, meaning certain customer specifications could not be fulfilled in-house.
“We often had to rely on external measurement services, which increased costs and risked delays in our production process. For a company with our reputation, the fear of losing follow-up orders or failing to meet the state of the art was a constant concern,” Florian Heimbeck added.
As customer expectations grew more stringent, Bharat ForgeCDP Gmb was at a crossroads. The company needed a solution that could measure complex, freeform surfaces with speed and the highest accuracy—all while empowering more employees to take part in the 3D measurement process and breaking the reliance on a handful of specialists.
Taking Metal Forming and Forging Innovations To New Heights With 3D Scanners
Determined to remain at the forefront of the market, Bharat Forge began searching for more modern 3D measurement technologies. The criteria were clear: Bharat ForgeCDP Gmb needed solutions capable of both tactile and optical measurements, independent of adhesive dots or surface sprays. Portability was key—the 3D measurement solutions needed to be versatile enough to measure components of all sizes and geometries without requiring the parts to be moved to a dedicated lab environment.
After evaluating several options, Bharat ForgeCDP Gmb chose Creaform’s 3D metrology solutions:
- MetraSCAN 3D: Optical and portable CMM 3D scanner
- HandyPROBE: An arm-free portable probing system designed for the shop floor
- VXinspect: Dimensional inspection software module
Transitioning to new technological solutions can be challenging for any organization, but Bharat ForgeCDP Gmb was determined to make the change as smooth as possible. After an implementation phase, which included training key users, Creaform’s solutions were ready to be put to the test. The first step was to develop relevant 3D measurement programs and analyze performance levels.
One huge breakthrough was training the rest of the staff. “We were impressed with how quickly our employees adapted to the new system,” Florian Heimbeck recalled. “Once our power users were trained, our other team members who were to use 3D scanners and software as part of our workflows were trained in just a few days.”
This marked a major shift for the company. Where only a select few specialists previously could operate the company’s former tactile system, now employees across different departments can contribute to the 3D measurement process. “It was a very short training period, given the complexity of our products,” Florian Heimbeck mentioned. “This allowed us to assign many more people to added-value work, boosting our overall efficiency.”
Substantial Time Savings, Increased Efficiency and Satisfied Customers
The impact of Creaform’s 3D metrology solution was felt almost immediately. The time needed to measure each component dropped dramatically, saving up to 75% of the time previously spent on 3D measurement tasks. “We used to spend up to two hours measuring a single complex component,” Florian Heimbeck described. “Now, that time has been reduced by 1.5 hours per task. It’s a game-changer for our production process.”
Because Creaform’s solutions were more straightforward, the company no longer depended on a small group of highly trained technicians. “With Creaform, five times as many employees can now be deployed for measuring,” said Florian Heimbeck. “We plan to expand this further with additional training, allowing us to take on more projects across multiple shifts.”
A case in point? Bharat ForgeCDP Gmb also fulfilled customer expectations. One specific project involved measuring an aluminum chassis component with free-form surfaces for a renowned OEM. The customer expected optical measurement for initial samples and tests during series production—a task that would have been nearly impossible with legacy systems. “Creaform 3D scanners and integrated software allowed us to meet the customer’s exact specifications while saving time and improving accuracy. It’s been crucial in maintaining our relationships and securing follow-up orders.”
The company is now looking to expand the use of Creaform’s 3D metrology solutions across other areas of the company. Upcoming projects include measuring a five-meter diameter gear wheel for a forging press and other large machine assemblies. “Our work with Creaform has fundamentally changed how we approach 3D measurement tasks,” Florian Heimbeck concluded. “We’re excited to explore even more possibilities as we integrate these technologies into other parts of our business.”
For more information: www.creaform3d.com
