Charting a course: Exploring the future of portable metrology

The manufacturing world rarely stands still. From the shop floor to the executive suite, the drive for greater efficiency, higher quality, and seamless integration is constant. Portable metrology has become a critical part of this evolution, empowering manufacturers to bring precision measurement directly to the part. However, the landscape is crowded with varying options, making it difficult to navigate and choose the right tool for the job the first time.

In a recent webinar, we explored how manufacturers can “chart a course” through the established and crowded, red ocean-like market of similar offerings. This familiar, but challenging environment demands constant efficiency and innovation, and a focus on the future of portable metrology. This blog captures the core ideas from that session and explores the challenges shaping the industry and the innovations that are defining its future – what could be described as a blue ocean strategy, focusing on creating new market space where players pursue innovation that unlocks entirely new value for their customers.

The evolution from stationary to portable measurement

Decades ago, quality inspection was a bottleneck. Parts were removed from the production line and taken to a dedicated quality lab, where a stationary coordinate measuring machine (CMM) would perform its analysis. This process was slow, inefficient, and created significant delays. If a part failed inspection, the entire production run up to that point could be compromised, leading to costly rework or scrap.

The introduction of portable measuring arms revolutionised this workflow. The idea was simple but powerful: take the measurement device to the part. This shift eliminated the need to stop production and move components, saving time and increasing throughput. This principle of portability continues to drive innovation, allowing for in-situ checks right on the shop floor or even inside a CNC machine, delivering immediate feedback and maximising efficiency.

Key challenges driving portable metrology innovation

Today’s manufacturing environments present a unique set of challenges that demand more from our measurement tools. These challenges are the catalysts for the next wave of innovation in portable metrology.

Unstable and demanding environments

Shop floors are rarely pristine. They are dynamic spaces with vibrations, temperature fluctuations, and potential contaminants. Measurement equipment must be robust enough to deliver accurate results despite these conditions. Technologies like dynamic scanning, which locks onto targets even if the part is moving, are essential. Likewise, equipment must be built to withstand industrial environments, with certifications like IP54 for dust and splash resistance and thermal stability to perform reliably in a wide range of temperatures.

Complex parts and accessibility

Modern components, especially in aerospace and automotive, feature intricate geometries, tight tolerances, and hard-to-reach features. A one-size-fits-all approach to measurement no longer works; now, versatile tools that can adapt are a requirement. Modular designs, such as interchangeable probes and scanners or wrists that can be reconfigured to access recessed cavities, provide the flexibility needed to inspect complex parts without compromise.

The need for speed and high throughput

Time is a critical resource in manufacturing. Inspection processes must be fast to keep pace with production. The development of advanced laser scanning technology, which can capture millions of points per second with wide scan stripes, has been a game-changer. These innovations drastically reduce inspection time, turning what once took hours into a task that can now be completed in minutes.

Pushing the boundaries: The next frontier of portable solutions

While probing and scanning have become standard, the industry is now pushing into uncharted territory. The portable arm is evolving from a simple measurement device into a versatile sensor carrier, opening up entirely new applications that go beyond traditional dimensional inspection.

Non-destructive testing on the go

One of the most exciting developments is the integration of non-destructive testing (NDT) capabilities with portable arms. Historically, inspecting the internal structure of a part for defects required sectioning it, a destructive and time-consuming process.

Now, by equipping a portable arm with an ultrasonic sensor, operators can perform NDT analysis directly on the part, right on the production line. Using the arm’s encoders for precise positioning, the system can map the internal integrity of a component, detecting voids or inconsistencies within composite materials or welds. This provides a complete picture of quality, both inside and out, without damaging the part. It’s a transformative solution that merges metrology with materials analysis, creating a new level of quality assurance.

Digitising touch with human-like sensitivity

Another groundbreaking innovation is the combination of large-volume scanning with high-resolution surface analysis. For applications requiring microscopic detail – such as analyzing scratches, corrosion, pitting, or weld beads – traditional scanning has limitations.

By integrating a tactile microscope sensor onto the arm, we can now capture surface data at a sub-micron level. An operator can scan an entire assembly with a laser scanner and then, in areas of concern, use the tactile sensor to create a highly detailed 3D patch of the surface topography. This “thumbprint” of data is seamlessly overlaid onto the larger point cloud, merging macro-level context with micro-level precision. This capability is invaluable for maintenance, repair, and overhaul (MRO) operations, especially in the aviation industry, where understanding surface defects is critical for safety and performance.

An integrated ecosystem that evolves with your needs over time.

Hardware innovation is only one part of the equation. Software plays an equally vital role in creating a powerful, data-driven, streamlined workflow. The future of metrology lies in an open and integrated ecosystem with data flowing seamlessly from capture to analysis to modeling.

By acquiring best-in-class software for reverse engineering and inspection, and by fostering integrations with leading software platforms, we are building a cohesive environment. This allows users the flexibility to work with the solutions they prefer while leveraging the full power of advanced hardware. Whether it’s reverse engineering a legacy part, performing a full inspection against a CAD model, or analysing complex surface data, a unified software strategy ensures that insights are actionable and processes are efficient.

Charting your course

The metrology landscape is dynamic, with new technologies and solutions emerging at a rapid pace – but it is important to remember that not all tools are created equal. Navigating this space requires a clear understanding of your specific challenges, from part size and accuracy requirements to budget and throughput needs. By focusing on solutions that are robust, versatile, and part of a connected ecosystem, you can build a quality process that not only meets today’s demands but is also prepared for the innovations of tomorrow.