Is optical 3D metrology really worth it – or do traditional methods still do the job just fine?

Our webinar "Who Needs Optical Metrology Anyway?” explored this with four highly practical examples. Here's a clear summary of when it makes sense – and when it might not.

1. Measuring Tiny, Fragile Parts – Without Contact

Micro gears in watches, thin-walled stents, delicate connectors: these are difficult or impossible to measure with contact tools without risking damage.

Optical 3D metrology uses light to capture high-resolution 3D models without touching the part. You get a precise digital twin for full analysis, ideal for:

➡️ Micromechanics, dental tools, microelectronics, fine instruments

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2. Non-Destructive Inspection of Micro-Holes – e.g., in Injectors or Cooling Channels

Parts like fuel nozzles or turbine blades often include holes smaller than 100 µm. Tactile probes can’t access these features – and cutting parts open isn’t ideal.

Optical systems capture both external and internal micro-features non-destructively, especially when CAD alignment and deep-focus optics are used. Applicable in:

➡️Aerospace, automotive, medical injectors, microfluidics

3. Surface Texture and Haptics – For Appearance and Performance

Phone cases, appliance housings, or trim panels need to look good and feel right. Optical metrology captures surface topography in full 3D, providing:

➡️ Areal roughness values (e.g., Sa)
➡️Detection of scratches, gloss differences, or non-uniform textures
➡️Objective, repeatable quality control for finishes

No physical contact means coatings and delicate finishes remain untouched.

4. Measuring Functional Surfaces – Like Thread Rolling Dies

In tooling or additive manufacturing, surfaces aren’t just visual – they’re functional. Thread dies, molds, or structured rollers need accurate profiles to perform.

Focus-Variation technology (used in advanced optical systems) handles steep flanks, rough textures, and reflective areas. It enables:

➡️ Full 3D profile measurement, wear analysis, pitch, flank angle, crest radius
➡️ Inspection of complex cutting tools, gear hobs, or textured AM surfaces