Bruker Alicona to Launch SensorX at EMO 2025
At this year’s EMO exhibition in Hannover, Germany (September 22–26, 2025), precision measurement expert Bruker Alicona will debut the SensorX, a newly developed high-precision 3D metrology sensor designed for seamless OEM integration. Demonstrating this next-generation technology in a real-world application, Bruker Alicona will showcase the SensorX fully embedded within the NaPrep cutting-edge preparation cell from Nagel Technologies GmbH.
SensorX World Premiere
The SensorX, OEM sensor powered by Advanced Focus-Variation, is Bruker Alicona’s first sensor engineered specifically for integration into third-party systems. Developed in close collaboration with a key customer and already in use in industrial production, SensorX now enters the wider market as a fully validated solution for inline and in-process metrology.
The sensor is built on Bruker Alicona’s Advanced Focus-Variation technology, incorporating innovations such as Focus Probing, Vertical Focus Probing, and a robust coaxial illumination system. Together, these features enable precise, contact-free 3D measurement of shape and surface, even on sharp edges and complex geometries, without the need for sample preparation.
“SensorX is a breakthrough in metrology integration. It enables manufacturers to equip their machines with world-class optical metrology and achieve full traceability and automation — directly at the point of production,” says Urban Muraus, General Manager at Bruker Alicona.
Robotic Cutting-Edge Preparation with Inline Metrology
NaPrep, developed by Nagel Technologies GmbH, is an automated brushing cell for selective, controlled rounding of cutting edges. Defined edge preparation extends tool life, improves chip flow and surface finish, and reduces the risk of chipping.
At its core, NaPrep uses a robotic system to process round tools (drills, milling cutters, threading tools) and inserts — including complex freeform geometries. Integrated optical sensors identify tool orientation, while intuitive setup routines enable rapid programming of new tool types. The system supports robot-based process control, automated wear compensation, and closed-loop operation with integrated metrology. Until now, these capabilities were based on Bruker Alicona’s RS25 sensor, also powered by Focus-Variation technology.
At EMO 2025, NaPrep will, for the first time, feature the newly developed SensorX, offering even greater measurement precision. This marks a significant evolution of the cell’s architecture, enabling fully autonomous edge preparation with traceable, repeatable results in manless production environments.
The SensorX is fully embedded within NaPrep, ensuring reliable edge detection, real-time process correction, and automated wear compensation — all within a single intelligent cell.
Through this cooperation, Nagel and Bruker Alicona combine two complementary competencies: advanced robot-based micromachining and automated high-precision metrology.
FocusX will also be presented on a five-axis setup with the Real3DUnitX, featuring the new Automatic Round Tool Alignment function. This allows users to define measuring positions directly on a tool’s CAD model. During measurement, the sensor automatically detects tool orientation and aligns the process with CAD data, enabling fast and automated inspection of complex round tools.
For more information: www.alicona.com