Optimising Production with Accurate Jigs and Fixture Assembly

In manufacturing, the difference between an efficient, profitable production line and one hit by delays often comes down to precision. Jigs and fixtures are essential tools in this process, holding components in place or guiding tools to ensure each part is created to exact specifications.

For businesses seeking reliable, repeatable results, the accuracy of jigs and fixtures is non-negotiable. The use of advanced metrology technologies are a huge advantage in this area. It also requires the right set of toolmaker skills, combined with the relevant knowledge of hardware and software.

In this article, we explore how precise jig and fixture assembly can optimise production lines, reduce waste, and improve product quality.

Why jigs and fixtures matter

Jigs and fixtures play a pivotal role in both manual and automated manufacturing environments. Fixtures hold workpieces steady, ensuring they remain in a fixed position, while jigs guide cutting or drilling tools to ensure consistency in operations. Without accurate jigs and fixtures, parts may end up misaligned, affecting the functionality and quality of the final product.

In sectors such as aerospace, automotive, and medical device manufacturing, precision is paramount. A small deviation can lead to costly consequences, including product recalls, potential safety risks, and production downtime. In high-stakes environments, accurate assembly of jigs and fixtures can determine a company’s reputation and competitive edge.

The role of metrology in jig and fixture assembly

Ensuring the precision of jigs and fixtures has traditionally involved skilled manual inspection and tooling. However, advances in metrology have changed the game. Technologies including laser trackers, structured light scanners, and coordinate measuring machines (CMMs), enable manufacturers to measure complex geometries with a degree of accuracy unattainable by traditional methods.

In jigs and fixtures assembly, metrology tools allow manufacturers to ensure consistency. 3D scanning and measurement tools capture highly accurate data, ensuring that each jig and fixture is identical to the next. This level of consistency is vital for companies producing high volumes, or parts that require tight tolerances. They also significantly reduce waste. This is because with precise assembly, fewer components fall short of specification. This is not only cost-effective but aligns with sustainability goals, by minimising material use and waste output.

Accurate jigs and fixtures ensure that production setups are quicker and smoother too. By using 3D metrology to measure and verify these tools, manufacturers can reduce the need for constant adjustments, streamlining production. 3D measurement tools also allow for ongoing verification that assists in quality control. They provide early insights into any potential misalignments or wear in jigs and fixtures. This capability allows manufacturers to carry out predictive maintenance, reducing the likelihood of unexpected downtime.

Improving manufacturing efficiency with 3D verification

High-quality jigs and fixtures are essential, but they don’t guarantee flawless production by themselves. By integrating metrology into the assembly process, you can achieve proactive quality assurance, reducing error rates and improving the overall efficiency of the production line.

For example, an automotive manufacturer will use jigs to assemble various components. By employing laser trackers or portable CMMs to regularly verify the positions of these jigs, operators can immediately identify and correct any deviations from the intended design.

This process eliminates small inaccuracies that, if left unchecked, could lead to larger, costlier problems later in production. The result is a smoother workflow, fewer interruptions, and a more reliable product.

Key considerations for jig and fixture accuracy

While the benefits of accurate jig and fixture assembly are clear, there are some key considerations to bear in mind when integrating 3D metrology into this process. The materials used should be stable and durable, to withstand repeated use and potential environmental changes, such as temperature fluctuations. Materials prone to wear or deformation will impact alignment over time, potentially negating any initial precision.

Regular calibration of both the jigs and fixtures themselves, as well as the metrology equipment, ensures ongoing accuracy. A proactive approach to calibration can catch issues early, reducing the risk of disruption. The training, skills and experience of teams should also be prioritised. Metrology tools require skilled operators who understand the intricacies of both the equipment and the assembly process. Investing in comprehensive training or partners means making the most of these technologies and interpreting results accurately.

Look to the future with 3D Solutions

As manufacturing continues to advance, the demand for precision will only increase. For industries where accuracy is vital, integrating metrology into jigs and fixtures assembly informs a forward-looking strategy. This approach ensures that you can maintain stringent quality standards, reduce waste, and improve production processes.

The choice to invest in precision is an investment in long-term operational efficiency, product quality, and brand reputation. Whether for a small batch or mass production, accuracy sets a high standard for modern manufacturing, enabling you to deliver reliable, high-quality products with consistency and confidence.

Our skilled team at 3D Solutions have worked with multiple disciplines of measurement, in sectors including automotive and aerospace. Our extensive knowledge and experience means we can carry out a variety of tooling installations on any scale, meeting the highest standards.

Get in touch today to speak to one of our team about your next project.

A Comprehensive Guide to the Benefits of Laser Scanning

Laser scanners are powerful tools in the continuously evolving field of 3D metrology. As industries strive for higher accuracy and streamlined workflows, the adoption of laser scanning technology has surged. It offers a wealth of advantages, capturing data quickly and efficiently, allowing for enhanced precision, improved speed and versatility.

As one of the most effective measurement solutions, laser scanning involves the use of laser beams to capture the shape, size, and geometry of an object or environment. This data is transformed into highly accurate 3D models that can be used for analysis, design, or quality control.

In this article, we discuss the benefits of laser scanning in areas from manufacturing to construction and research.

Precision and accuracy

One of the most compelling reasons to adopt laser scanning technology is its unparalleled precision. These reliable devices can capture millions of data points within seconds, creating a highly detailed 3D representation of the scanned object or environment. This level of accuracy is particularly valuable in industries where tolerances are tight. This is because any deviation from the original design can result in costly errors.

Laser scanners excel in capturing complex geometries, which require advanced measurement solutions. Examples of this include curved surfaces and intricate details, which may be difficult or impossible to measure using traditional methods. With the ability to measure objects at the micrometre level, laser scanning provides peace of mind that even the most minute variations are detected.

Speed and efficiency

In today’s fast-paced industrial landscape, efficiency is a top priority. Laser scanning facilitates rapid data acquisition, significantly reducing the time spent on measuring and inspection tasks. This is particularly beneficial in large-scale projects, such as construction sites or manufacturing plants. In these environments, traditional measurement methods could take days or even weeks.

The ability to capture a complete data set in a matter of minutes not only saves time but also reduces the risk of human error. Once the data is collected, it can be processed and analysed in real time, enabling quicker decision-making and minimising downtime in production or project workflows.

Non-contact measurement

One of the key advantages of laser scanning is that it is a non-contact measurement method. This makes it ideal for inspecting delicate or complex objects, which could be damaged by traditional probing techniques. Whether you’re scanning fragile historical artefacts or soft materials in manufacturing, the non-invasive nature of laser scanning ensures the integrity of the object is preserved.

This non-contact approach also extends to locations where access may be difficult or hazardous. In these cases, laser scanners can measure from a distance. This makes them ideal for eliminating impractical or unsafe direct contact, around large structures or environments.

Versatility across industries

Laser scanning technology is endlessly versatile and can be implemented across a wide range of industries. In manufacturing, it is commonly used for quality control and reverse engineering. By comparing scanned data with CAD models, manufacturers can ensure that components are produced to exact specifications. The ability to reverse engineer products also allows companies to recreate parts where original designs may no longer be available.

In construction and civil engineering, laser scanning is instrumental in creating accurate 3D models of buildings and infrastructure. This can be used for planning, monitoring construction progress, or assessing the condition of existing structures. Laser scanning is also a valuable tool in heritage preservation, allowing historical buildings or artefacts to be documented in detail without physical intervention.

Other industries that benefit from laser scanning include aerospace, automotive, oil and gas.

Comprehensive data capture

Unlike traditional measurement methods, which often focus on specific points or dimensions, laser scanning captures an entire surface or area in one go. This comprehensive data capture allows for more detailed analysis, providing a complete 3D record of the object or environment being scanned.

This level of detail is invaluable for tasks such as deformation analysis, where changes over time need to be monitored. Similarly, for capturing the current condition of an asset before modifications are made. The ability to retain a complete digital copy of an object or site also supports long-term data archiving. It means that accurate records can be made available for future reference or comparison.

Seamless integration with CAD and digital workflows

In today’s digital age, seamless integration with CAD software and other digital workflows is essential. Laser scanning data, typically in the form of point clouds or meshes, can be easily imported into CAD systems for further analysis, design, or simulation. This compatibility lets laser scanning fit naturally into existing workflows, without requiring significant changes or additional software.

The ability to integrate with digital tools also opens up possibilities for advanced simulations, virtual reality visualisations, and augmented reality applications. For instance, architects and engineers can create digital twins of buildings or environments, for a dynamic and interactive way to explore designs or assess conditions.

Improved project outcomes

The use of laser scanning not only improves efficiency and accuracy, it also leads to better overall project outcomes. With highly detailed data available at every stage, stakeholders can make more informed decisions, reduce rework, and avoid costly mistakes. The ability to capture data in real-time also means issues can be identified early, allowing for immediate corrective actions to minimise disruption.

The use of 3D scanning with lasers provides a clear, intuitive way for project teams to communicate. Whether it’s comparing as-built conditions to design plans or visualising future modifications, the enhanced clarity and detail afforded by laser scanning help ensure everyone is aligned.

Discuss how laser scanning can benefit your project

Laser scanning has transformed the way industries approach measurement and analysis, providing an efficient, accurate, and versatile solution for a wide range of projects. From capturing detailed 3D models to enhancing digital workflows, the benefits of laser scanning are clear. As the technology continues to evolve, it will play an increasingly integral role in helping companies meet the demands of modern engineering and manufacturing.

Investing in the latest 3D scanning laser scanning helps you remain competitive in today’s data-driven world. As a result of this technology, your business benefits from faster processes, improved accuracy, and enhanced decision-making capabilities.

Contact us at 3D Metrology Solutions to discuss our range of laser scanners for hire.

The Advantages of Portable Arm Inspection for On-Site Measurements

In today's fast-paced manufacturing and engineering environments, accurate and reliable 3D measurement solutions are critical. Their main benefits are around helping to maintain product quality and ensuring compliance with industry standards. While traditional inspection methods have their place, the advent of portable arm inspection systems has changed everything. Portable CMMs have revolutionised how companies approach dimensional analysis, especially for on-site applications.

At 3D Metrology Solutions, we understand that choosing the right tools for the job is crucial. Portable arm inspection systems offer an appealing alternative to conventional methods, providing flexibility, precision, and cost efficiency in one package.

In this article, we’ll explore the key advantages of portable arm inspection for on-site measurement solutions. We’ll go into more detail about why many industries are now adopting this technology for their projects.

Flexibility and portability

One of the most significant benefits of portable arm inspection systems is their flexibility. Unlike large, stationary coordinate measuring machines, which require parts to be brought to them, portable CMMs can be taken directly to the measurement site. This feature is invaluable for inspecting large components, machinery, or structures that can’t be easily moved.

Whether you’re working in aerospace, automotive, or heavy industries, the ability to carry out measurements directly on the shop floor, or in the field, saves considerable time and resources. Portable CMMs are designed to be lightweight and easy to transport, making them ideal for use across multiple locations.

Enhanced precision and accuracy

While portability is a key advantage, accuracy is never sacrificed. Modern portable arms are equipped with high-precision sensors that allow for reliable 3D measurement. This ensures that the data collected from a portable CMM is the same quality as that of a fixed CMM.

With advances in probe technology, these systems can capture complex geometries with micrometre-level precision. This is particularly important for industries where tolerances are tight, as even the smallest deviations can lead to costly errors or safety concerns. By employing portable arms, you ensure that quality control processes remain robust, no matter the environment.

Time and cost efficiency

Efficiency is at the heart of every successful business. The ability to perform on-site measurements significantly reduces downtime, with no need to disassemble parts or transport them to a dedicated inspection facility. This leads to faster turnaround times, allowing for quicker decision-making and corrective actions.

Portable arm inspections can be performed by skilled operators, too. Without the need for an extensive setup, both labour and equipment costs are reduced. For industries that require regular inspections, this is a substantial advantage, streamlining workflows and reducing overheads.

Versatility in applications

Portable arm systems are highly versatile, capable of handling a wide range of applications across different sectors. From reverse engineering and quality control to alignment and assembly verification, these systems provide a comprehensive solution for many metrology needs. The ability to switch between different probes and 3D scanning options further enhances their adaptability. This allows operators to measure complex parts with a single tool.

Industries such as shipbuilding, construction, and energy sectors benefit from the adaptability of portable arm systems, where large-scale structures or intricate assemblies are often involved.

Real-time data and reporting

In today's digital age, data is everything. Portable arm inspection systems provide real-time data collection, allowing you to view and analyse results on-site. This immediate feedback allows for quicker adjustments, reducing the likelihood of defects and improving overall production quality.

Additionally, advanced software solutions that accompany these systems enable seamless integration with existing digital workflows. Measurements can be easily recorded, compared to CAD models, and incorporated into larger data sets, ensuring that inspection processes remain consistent and traceable.

Improved safety and convenience

In many industries, safety is a paramount concern. The ability to conduct inspections on-site, particularly in hard-to-reach or hazardous areas, reduces the need for potentially dangerous transportation of large or sensitive components. Portable arm systems are often used in environments where large machinery or critical infrastructure is being inspected, because they facilitate safe and convenient measurement solutions.


Find out how portable arm inspection can benefit your business

Portable arm inspection systems represent a significant leap forward in the field of 3D metrology, offering unmatched flexibility, accuracy, and efficiency for on-site measurements. They’re fast becoming a staple across many industries, providing an effective solution for quality control, reverse engineering, and more.

For companies looking to streamline their inspection processes, portable arm systems offer a valuable combination of precision, portability, and cost-effectiveness. As technology continues to evolve, these tools will become an even more integral part of modern metrology practices. They’ll continue to help businesses maintain the highest standards of quality in increasingly competitive markets.

By adopting portable arm inspection technology, you can be at the forefront of innovation while optimising your time and resources.

Get in touch today if you want to speak to us about measurement solutions with proven success, including 3D scanning and portable CMMs.

How Laser Tracker Inspection Ensures Precision in Manufacturing

Laser tracker inspection is a valuable technology for ensuring precision in manufacturing processes. This advanced measurement system uses a laser beam to accurately measure the three-dimensional coordinates of an object. This allows you to obtain highly precise data that can be used for various quality control and alignment tasks.

Laser tracking systems are capable of measuring with extreme accuracy, often within micrometres. This level of precision is critical in industries where small deviations can lead to significant issues, such as aerospace, automotive, and high-precision machining. By using a laser interferometer or Absolute Distance Meter (ADM), laser trackers can measure distances with high precision, ensuring that parts are manufactured to exact specifications.

By providing precise, reliable, and versatile measurement capabilities, laser tracker inspection helps you ensure that your products meet stringent quality standards and are produced efficiently. This is a critical component of modern quality assurance in manufacturing, helping to reduce errors, improve product quality, and enhance overall productivity.

Understanding the accuracy and precision of laser trackers is crucial for making informed decisions about their use in your projects. In this article, we’ll explore how laser tracker inspection ensures precision in manufacturing.

Measurement accuracy

This can fall into two categories, the first being linear accuracy. This refers to the closeness of the measurements to the actual value. For laser trackers, linear accuracy is typically specified over a certain distance. For example, a specification might state an accuracy of ±10 micrometres at a distance of 10 metres. This means the measured position can deviate by up to 10 micrometres from the true position at that range.

Then there’s angular accuracy, which defines the precision with which the laser tracker can measure angles. This is crucial for determining the orientation of components. Angular accuracy is usually specified in arcseconds (1 arcsecond = 1/3600 of a degree). For instance, a tracker might have an angular accuracy of ±1 arcsecond, indicating a very fine level of angular measurement.

Repeatability

Firstly, single point repeatability measures the laser tracker's ability to return to the same point in space after repeated measurements. It's an indication of the consistency of the device, often specified in micrometres. For example, a repeatability of ±2 micrometres means the tracker can reliably return to the same point within a 2-micrometre range.

The volumetric accuracy represents the accuracy across the entire measurement volume. It's a combination of linear and angular accuracies, providing a more comprehensive picture of the system's overall accuracy.

Environmental conditions

The environment can affect decisions around the right laser trackers in various ways. Many laser trackers include systems to compensate for temperature changes, which can affect measurement accuracy. It’s important to know the operating temperature range, and the device’s ability to compensate for thermal expansion, for ensuring accurate measurements in varying conditions.

Accuracy can also be impacted by the sensitivity of the laser tracker to environmental factors, such as humidity, vibration, and air pressure. Specifications might include permissible ranges for these factors.

Measurement range

Know the maximum distance over which the laser tracker can accurately measure. For instance, some trackers can measure up to 80 metres or more. This is vital for planning measurements in large-scale projects.

You or your service provider should also check the minimum range, which is the closest distance at which the laser tracker can effectively operate. This is crucial for projects involving small-scale components or fine details.

Calibration and certification

The calibration frequency gives information on how often the laser tracker needs to be calibrated to maintain accuracy. Regular calibration ensures the device's measurements remain reliable over time.

Check the traceability too, which is the ability of the measurements to be traced back to national or international standards. This is essential for quality assurance and compliance with industry standards.

Data resolution

The resolution indicates the smallest detectable change in measurement. A higher resolution indicates finer measurement capability. For example, a resolution of 0.1 micrometres means the tracker can detect changes as small as 0.1 micrometres.

Real-time data collection

Laser trackers provide real-time data collection, which allows for immediate feedback and adjustments during the manufacturing process. This capability is crucial for identifying and correcting errors as they occur, reducing the risk of defective products and minimising waste.

Measurement uncertainty

The measurement uncertainty encompasses all potential errors in a measurement, including equipment, environmental, and procedural errors. Understanding the total uncertainty helps in assessing the reliability and validity of the measurement data.

Performance specifications

The dynamic performance gives information on how the laser tracker performs under dynamic conditions, such as tracking a moving target. This includes the maximum speed of target movement that can be accurately tracked.

Versatility and range

The flexibility of laser trackers allows them to measure objects of various sizes and shapes, from small components to large machinery. They can operate over long distances, often up to several tens of metres, making them suitable for large-scale manufacturing environments.

3D measurement and alignment

Laser trackers can perform three-dimensional measurements, which are essential for ensuring the proper alignment and assembly of parts. They are often used in conjunction with software to align machinery, calibrate tools, and verify the dimensional accuracy of components. This capability ensures that assemblies are built correctly and will function as intended.

Non-contact measurement

As a non-contact measurement system, laser trackers do not physically touch the parts being measured. This is particularly important for delicate or sensitive components that could be damaged by contact. Non-contact measurement also avoids the introduction of mechanical stress, or deformation that could affect the accuracy of measurements.

Automation and integration

Laser trackers can be integrated into automated manufacturing systems, allowing for continuous monitoring and inspection. This integration supports high-speed production lines. By providing rapid, accurate measurements without manual intervention, they support consistent product quality.

Data logging and analysis

The data collected by laser trackers can be logged and analysed to improve manufacturing processes. This information can be used for statistical process control, trend analysis, and root cause investigation, helping you to continuously improve operations and maintain high-quality standards.

Data processing software shows the capabilities of the software used for data analysis. This includes how it handles data correction, filtering, and visualisation. Understanding the software's features helps in assessing the ease of use and accuracy of data interpretation.

Complex geometries and large-scale metrology

In industries like shipbuilding and aerospace, where large structures and complex geometries are common, laser trackers are invaluable. They enable precise measurement of large components, ensuring that they fit together perfectly and perform as required.

Get in touch today if you want to speak to us about laser tracker hire, or our laser tracker inspection services.