NIKON METROLOGY NEWSVOLUME 12

Patient-specific implants made affordable

Revolutionizing defect analysis for electronic components

Industrial CT to research green energy solutions

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4 | Ultra-fast scanning and uncompromising detail with the ModelMaker H120

6 | First class CT inspection advances the production of 3D printed medical implants

9 | iNEXIV video measuring system brings process repeatablility to within single-figure microns

12 | Nikon’s ‘measuring’ technology contributes to Toyota’s environment & safety

14 | Pressings subcontractor replaces two CMMs with one video measuring machine

17 | Using Nikon's measuring technology for sub-contract inspection

20 | Accelerated inspection cycles help Quality Needles recover investment cost within one year

22 | DTU Energy uses industrial CT to research the development of green energy solutions

24 | Next-generation shop floor CMM for car body inspection

27 | Nikon swiftly integrates customer-specific measuring and inspection processes

30 | Mindarika adopts microfocus CT to inspect automotive components

32 | Precision meets productivity for aerospace component inspection

34 | Revolutionizing defect analysis for electronic components

Content

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22 years since the inception of the ModelMaker product line, the cutting-edge ModelMaker H120 firmly pushes the ever-exacting boundaries of handheld laser scanning. Incorporating blue laser technology, ultra-fast frame rate, specially developed Nikon optics and the ability to measure the most challenging materials this represents the next generation of portable laser scanning. The H120 makes no compromises in addressing the market needs by efficiently delivering the most detailed and accurate data in a fraction of the time of competing technologies.

Portable productivity

High productivity for challenging applicationsWith a Field-of-View width up to 120 mm and a point resolution of up to 35 μm, the ModelMaker H120 is the perfect fit for users requiring fast data collection over a large area but cannot afford to compromise on detail.An extremely fast frame rate of over 450Hz is available even when measuring difficult materials such as carbon fibre, gloss black, reflective or significantly multi-coloured parts. The ModelMaker H120’s uncompromising speed is completely independent of its robust ability to capture high quality data on the most challenging parts. With 2,000 points per scan line and no reliance on point-to-point interpolation to artificially boost data density it is possible to measure very small details on large surfaces even when cycle time is critical. So whatever the application, users can be confident that the productivity and clarity of the data remains at the highest level.

Performance meets detail and accuracyTo complement such high productivity, the ModelMaker H120 uses advanced Nikon optics and a blue, low speckle, laser to give very high accuracy and low noise data. This means it is now possible to clearly identify very small scratches and abrasions on a surface. As well as the shape of the surface, sharp edges are represented like never before. With a scanner accuracy of 7 μm (1σ) and a combined system accuracy with the MCAx arms of up to 28 μm (2σ) the ModelMaker H120 stands far apart from other similarly perceived solutions.The 4th generation of Enhanced Sensor Performance (ESP4) dynamically adapts the laser parameters not just for every scan line, but for every point in each scan line – enabling parts with significant colour changes or reflectivity to be measured from any angle. This fast-tracks the user’s confidence with the system and minimises training needs since a single scanner setting is capable of measuring almost all parts encountered in industrial metrology applications.

Efficient and easy to useThe new ModelMaker H120 has been designed to provide users the most efficient, user-friendly and accurate measurement experience on the market. Temperature compensation and robust thermal stability mean warm-up time to achieve a stable set-up is unnecessary. Simply connect to the PC using a USB cable, power on and start scanning within a few seconds. Real-time feedback is provided by display of the boundaries of the measurement area on the measured part which ensures the user is always scanning at the optimal position. An integrated locking mechanism provides a simple, user-friendly and repeatable connection to the MCAx arm. This allows the scanner to be used on MCAx arms of different sizes and specifications located throughout a facility rather than needing to move the whole arm assembly.

Ultra-fast scanning and uncompromising detail with the ModelMaker H120

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Results you can be confident inWith handheld laser scanning, users can rapidly and easily understand the dimensional quality of their company’s products both inside the metrology lab or on the shop floor. By combining the portability, accuracy and application flexibility of the MCAx arm with the extreme performance capabilities of the ModelMaker H120, users can achieve precise measurements with confidence in a multitude of situations.Through direct integration with a variety of class-leading software tools for scanning, probing, processing and dimensional analysis of measurement data – users can tailor the solution for their needs. No matter whether the application is: advanced inspection using Geometric Dimensioning and Tolerancing (GD&T) with colour map comparisons to nominal CAD, fly-outs and sectional cut-throughs; reverse engineering to recreate existing parts; or even simply using high-definition scan data to generate polygon meshes for additive manufacturing – the ModelMaker H120 delivers on all fronts through its no-compromise design and Nikon Metrology’s superior laser scanning development experience.

Multi-sensor measurement at your fingertipsBy combining the ModelMaker H120 scanner with the high performance MCAx arm, the combination of non-contact scanning and contact probe measurement allows users freedom to measure almost anything, including freeform and geometric parts, hard-to-reach features, highly textured or transparent materials and even materials which deform easily such as foams or textiles. In many cases of industrial feature measurement, the accuracy performance and low noise level of the new scanner significantly exceeds the performance of tactile probes.

High-accuracy blue laser technology

• Measure the smallest details on the largest surfaces even when cycle time is critical

• Whatever the application, users can be confident that the productivity and clarity of data is of the highest order

Efficient measurements

• Users can rapidly and easily understand the dimensional quality of their products both inside the metrology lab and on the shop floor

• The ModelMaker H120 provides users the most efficient, accurate and user-friendly measurement experience on the market

Superb data quality for the most challenging parts and surfaces

• Parts with significant colour changes or reflectivity can be measured accurately from any angle

• Combining non-contact scanning and contact probe measurement allows users freedom to measure freeform and geometric parts to hard-to-reach features, highly textured or transparent materials prone to deformation

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Ortho Baltic, a manufacturer of patient-specific medical implants recently invested in additive manufacturing and CT inspection technology. It is vital for such components to be of outstanding quality, therefore an assured quality control system is integral to the company’s success.

Patient-specific implants made affordable

Ortho Baltic is a medical company based in Kaunas, Lithuania and is the first patient-specific TMJ (temporomandibular joint) endoprosthesis manufacturer in the Baltic states, and one of three in the whole of Europe. ‘Endoprosthesis’ is an artificial joint implant. It is used to replace the loss or lack of functionality of a joint in the body.

In its mission statement, there are two challenges: to change the thought paradigm from “the same implant fits all”, to an individual patient specific view. And to make patient-specific implants affordable for all patients and national healthcare systems in terms of price and delivery.

In 2012, the company invested in additive manufacturing technologies. It expanded its made-to-order services to the design and production of patient specific joints, cranial and spinal implants bone plating systems, dental and jaw restoration implants and patient-specific surgical guides. For these purposes, Ortho Baltic deals in one-off production and requires one-off inspection of the 3D printed components.The team at Ortho Baltic consists of a variety of experts. Whilst employing highly qualified biomechanical,

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First class CT inspection advances the production of 3D printed medical implants

Case study

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mechanical, material science and IT engineers, it also works closely with hospitals, surgeons and radiologists. Ortho Baltic cooperates with Lithuanian University of Health Sciences and University Hospital, Klaipeda University Hospital, Vilnius University, Kaunas University of Technology, Riga Technical University.

3D printing bespoke medical implantsRequiring a limitless production method that enables complete flexibility in design iterations, 3D printing was the stand out solution for the needs of Ortho Baltic. It offers infinite flexibility and is able to bring complex designs or forms to reality at a far more affordable cost than ever before. Investing in the latest technology lead to the establishment of its Implant Design and Development Centre consisting of various additive manufacturing and quality control equipment.

Ortho Baltic uses a variety of additive manufacturing processes for the different kind of components produced. Typically, implants are made from the medical Grade-5 titanium alloy Ti6Al4V by direct laser metal sintering (DMLS). For its single-use patient-specific surgical guides and implant models a biocompatible polymer PA 2200, also known as Nylon-12 is used for selective laser sintering (SLS).

X-ray plays an important role in the process from start to end. The medical X-ray CT scans are the basis to prepare the CAD model while

the quality inspection of the AM parts is verified with an industrial high voltage micro-CT scanner.

Milda Jokymaityte – Clinical Engineer at Ortho Baltic explains the process by saying, “To create the patient-specific anatomical models, 3D reconstruction engineers work with a radiologist (if necessary) using the patient’s radiological data to perform a 3D reconstruction. The anatomical bone structures are segmented and virtual 3D models are prepared”.

Milda continues, “Including printing, quality control, packaging and sterilization, the usual lead time for a patient-specific TMJ is approximately four weeks following the surgeon’s approval of final design. From this point onwards, the pre-surgical planning commences between patient and surgeon, ultimately leading to surgery completion.”

Micro-CT: the quality assurance solution for additive manufactured medical implantsThe capabilities of 3D printing are there for all to see, but an important challenge is the assurance of quality in additive manufactured components. Especially in the medical field, the quality, fit and functionality of implants and other medical devices is vital. Domantas Ozerenskis – Product Quality Manager at Ortho Baltic explains that “For today, micro-CT is the best solution for our product development and quality control”. He

continues, “3D printing is a very complicated technology and has a big variation of processing parameters, consequently it is hard to predict the structure quality and geometry of a printed part”.

The implementation process for the patient-specific implants is referred to as a pre-planned treatment solution. For this method, the whole procedure must be planned down to the last detail, so that it’s as simple as putting the prosthesis in place. For this reason, it is crucial to be 100% sure that implant geometry is exactly the same as the CAD model.

Non-destructive inspection of titanium prosthesesFor Ortho Baltic, micro-CT was the outstanding quality assurance system for inspecting additive manufactured components. Domantas explains that “a CMM especially with tactile probing is inconvenient for non-parametric measurements, also there is no possibility for inner structure investigation.” He continues, “The inner quality of implants determines the mechanical resistance of the part, and micro-CT is the only non-destructive way to check for voids and cracks inside of the part.”

High power CT, micro-focus accuracy and the non-destructive nature of CT were the requirements that would provide the engineers at Ortho Baltic a full, comprehensive and unparalleled insight into the conformity of its products. The first requirement for the

“ An implant with Nikon CT quality assurance is more reliable and easier to prove its value.” Domantas Ozerenskis, Product Quality Manager at Ortho Baltic.

An example patient-specific endoprosthesis fixed onto a jaw.

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equipment was to be able to penetrate the titanium components. For this, Ortho Baltic needed at least a 200 kV energy source, for sufficient power to scan the dense materials. The secondary requirement was for the system to have a large enough working area. With Ortho Baltic’s components varying for each patient and each procedure, a platform capable of holding a range of large or heavy components was needed.

The Nikon Metrology system Ortho Baltic settled on was the XT H 225, with Varian

4030 digital panel and Inspect-X software. The XT H 225 working area is able to hold large sample sizes and weights up to 15 kg. The 225 kV micro-focus source also offers sufficient energy for penetration of the dense materials including titanium alloy, from which the implants are made.

An irreplaceable quality control toolA current challenge in additive manufacturing industries is deploying a comprehensive inspection solution to verify the individual products. However, micro-CT presents itself as the answer. For Ortho Baltic, the XT H 225 suits all requirements of a quality control system.

Very impressed with the whole service, Domantas attests to Nikon’s professionalism by saying, “The installation and training was very successful, trainers were very high level engineers. The maintenance is also very quick and professional, we have nothing to worry about”.

The CT system has helped Ortho Baltic in its mission to make patient-specific implants affordable and widely available with successful procedures already having been completed. In comparison to standard implants previously sourced from the United States, Ortho Baltic has been able to produce these patient specific implants at almost half the cost. It is important to stress that despite the ability to produce implants for much cheaper, the quality is in no way sacrificed. From a recent article following a procedure, maxillofacial

surgeon – S. Bojarskas explains that aside from needing more extensive planning, the product itself is no different in terms of quality.

Domantas discusses how the XT H 225 is a fundamental quality control tool for Ortho Baltic by saying, “Nominal (CAD) to actual 3D printed implants comparison, geometry inspection and void detection is very useful and irreplaceable for the quality control of our application. The Nikon solution offers better knowledge of what we are manufacturing. It gives better precision and understanding of 3D printing errors and deviations.”

In most cases of 3D metal printing, post-processes such as sandblasting and polishing take place. What micro-CT has also helped to show is that these processes often remove thick surface layers up to 200 microns and even thicker for manual processes. Domantas explains, “This micro-CT data allowed us to adjust our CAD and 3D printing protocols to get the most accurate geometry for all 3D printed parts”.Very impressed with the service from Nikon Metrology, Domantas concludes by saying, “An implant with Nikon quality assurance is more reliable and easier to prove its value”.

Following the successful installation, Ortho Baltic not only performs quality control for implants, but also applies this technology for the activities of various national and international scientific researches and projects.

The final result: patient-specific TMJ (temporomandibular joint) next to its deviation model where the CT results are compared to the orginal CAD file.

XT H 225 at Ortho Baltic, LithuaniaOrtho Baltic uses the XT H 225 for quality inspection of patient-specific medical implants produced by additive manufacturing.

• 225 kV micro-focus source enables penetration of the medical grade-5, dense titanium alloy used in Ortho Baltic’s implants

• CT scans reveal all internal voids and defects of the complex internal features of additive manufactured components non-destructively

• CAD comparison enables CT scans to be compared with CAD design for inspection of deviations

• Working area can hold large and heavy material samples for effective inspection

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iNEXIV video measuring system brings process repeatablility to within single-figure microns

Novel method for measuring the length of free-form springs

How do you determine the diameter of a seal energising spring after manufacture, while it is still an irregular loop of coil with its ends welded together and not yet formed into a circle by the seal it will eventually strengthen? The standard options are traditional circular go / no-go gauges for a specific size of large spring or a conical step gauge rising in one millimeter increments for a family of smaller sizes. However, Redditch-based Clifford Springs has established a more accurate process using a Nikon Metrology iNEXIV VMA-4540 CNC video measuring machine, installed in May 2016.

Case study

To a repeatability measured in single-figure microns, the optical measuring equipment automatically determines the length of a free-form loop of coiled spring to determine what its circumference will be when it is circular, after which dividing by pi produces a precise result for the diameter.

Clifford Springs now plans to use the iNEXIV VMA-4540 to count automatically the number of coils per unit length of spring, looped or unwelded, which predicts its load deflection characteristics in use. Compared with the present method of manually counting the number of coils in a given length and using a formula to extrapolate the total number for the whole spring, the optical method will be more precise.

Furthermore, measuring the angle between successive coils in a spring and their distance apart will be more

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accurate, as well as much faster, than current manual procedures using an optical profile projector. Another important benefit is that an automated system eliminates the risk of human error.Managing director John Clifford commented, “Customers are increasingly asking for reports with proof of the numerical values from our inspection of the springs we manufacture, but only transcription of manually measured results was previously possible.

“Since May this year, the Nikon optical measuring machine has allowed us to print off actual readouts of spring diameter and soon coil count and geometry will be included. It has enhanced the perception of our metrology expertise amongst our customers and increased the confidence they have in our products and reports.”

Different inspection systems investigatedPaul Thomas, development engineer at Clifford Springs commented, “We considered

several alternative systems for automating the inspection of our springs. They included blue and white light scanners, but they are better for comparative rather than absolute measurements, and traditional optical profile projectors, which are too reliant on manual intervention.

“Tactile metrology on a coordinate measuring machine (CMM) was discounted, as touch-probing would move the spring during inspection. Trials were carried out using a laser scanner on a CMM, but the resulting point cloud gave profile data that was difficult to translate into a length measurement.

“So an optical video measuring system was really the only option and we looked at three or four potential suppliers. The Nikon Metrology iNEXIV solution was the only one that worked successfully and has since proved very satisfactory in operation.”He went on to explain that Nikon Metrology helped Clifford Springs to co-develop a novel method for measuring a spring’s length. The iNEXIV’s AutoMeasure software instructs the

2D measuring head to follow the contour of the loop automatically, repeatedly reorientating itself and taking coordinates of points at the same height at intervals around the outside (or inside) of the spring. The operator simply has to enter the start point, end point and measurement pitch.

Every measurement is taken at the peak of an individual coil of wire, which is automatically recognised, rather than in the adjacent troughs, so that the true outside or inside diameter of the spring is obtained. Between 500 and 1,000 sets of coordinates are captured, depending on the size of the spring.

Successive points are linked around the entire loop to create a series of very small, straight lines which are added together to determine the length, ie circumference of the spring. To allow for the fact that it is the arcs between the points that should really be totalled, AutoMeasure introduces a small correction factor that increases the measured length to arrive at the true circumference.

“ So an optical video measuring system was really the only option and we looked at three or four potential suppliers. The Nikon Metrology iNEXIV solution was the only one that worked successfully and has since proved very satisfactory in operation.John Clifford, Managing director at Clifford Springs

Close-up views of spring measuring in progress.

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Each result is not only very accurate but also highly repeatable. If the shape of the same loop is altered on the iNEXIV table and the measurements are taken again, the lengths recorded have consistently been shown to be within a few microns of each other.

Versatility of the iNEXIV platformThe iNEXIV VMA-4540 at Clifford Springs is currently employed exclusively for two-dimensional inspection. The instrument does, however, have optical auto focus (AF) using the instrument’s generous 73.5 mm working distance, allowing measurement of depth. The facility is not used at the moment, as coil width is easily determined manually using a vernier caliper, but it remains a possibility if the manufacturer decides to increase the level of automation in the inspection of its products.

It is possible to fit a touch probe for capturing point data if, for example, sloping faces or undercuts need to be inspected. The probe is offset from the optical axis but works in the same 450 x 400 x 200 mm coordinate space,

with only slightly reduced operating range. A stylus changer is provided, so it is feasible to mix optical and tactile measurements in the same cycle. The instrument’s versatility is further enhanced by a variety of illumination options based on episcopic, diascopic and eight-segment ring LEDs. Combining these enables accurate detection of low-contrast edges.

Clifford Springs currently uses only a fraction of the iNEXIV’s potential functionality. However, it is reassuring for them to know that its new metrology platform is highly capable and suitable for fulfilling virtually any measuring task that may be required in the future.

A traditional go / no-go gauge for establishing the ID and OD of a specific size of seal energising spring is shown in the foreground. Pictured behind is a conical step gauge rising in one millimeter increments for measuring the diameters of a range of smaller spring sizes. Such hard gauging has been supplanted by the Nikon Metrology iNEXIV VMA-4540 video measuring machine at Redditch-based Clifford Springs.

Nikon Metrology’s AutoMeasure software drives the iNEXIV VMA-4540. The software automatically calculates the circumference after individual measurement of a coil spring.

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The measurement time was drastically reduced. Even unnecessary materials were eliminated. Automobiles are composed of tens of thousands of components. One of the most important of these is the gears that transmit the energy generated by the engine to the wheels, which greatly affects the safety of the automobile itself, and the stability of the run. Toyota Motors, with their intentions to Kaizen (continuous improvement) activities has accumulated their efforts in diligently researching and developing the ideal gears. “In recent years, with the popularization of quiet running automobiles such as hybrid cars and fuel cell cars, reducing the noise from the bad engagement of gears is becoming an increasingly important issue,” tells us Yoshikatsu Shibata, who manages the design/quality assuarance of the gears and the development of testing equipment at Toyota Motors.

Nikon is well-known not only for the production of personal products such as cameras, but for producing many industrial equipments with their leading-edge optical/precision technologies. Their distinguished equipments also contribute to the improvement of environmental performance and safety of automobilesand airplanes. We will report the frontline of “Nikon’s technologies that contribute to society” in a series of two articles.

Special interview

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The reason Toyota, continually making Kaizen (continuous improvement) activities, chose Nikon as their partner

Nikon’s ‘measuring’ technology contributes to Toyota’s environment & safety

13News I Volume 12

With the gears in smooth engagement, the uncomfortable noise will be reduced. But to realize this, extremely sophisticated measurement technologies will be required. “Although they may seem similar to the naked eye, the shape and posture of each single tooth flank differs by micrometers. To completely eliminate the cause of the noises, every tooth flank must be measured accurately.” (Mr. Shibata) Toyota Motors conventionally performed these measurements using contact type metrology systems. With this method, each sample was literally directly contacted to measure its shape, length, height, etc.

However, this method had its difficulties. The tooth flanks are measured by equally spaced “points,” then connected with “lines,” and therefore if the distance between the lines is too wide, “measurement oversights” are more likely to occur. But then if the number of lines is increased to avoid oversights, the number of times of contact increases, and the time required for measurement becomes longer.

“It took us hours to complete the measurements at the precision required by our company. Just when we were thinking, couldn’t there be a way to complete the

measurements at this precision within a shorter time, we met the “High-precision Non-contact Sensor 3D Metrology System.” (Mr. Shibata)

With this system, which can irradiate the laser from various angles without contacting the sample, the entire sample could be measured by “planes” instead of “points and lines,” and not only did measurement accuracy dramatically enhance, but measuring time was drastically reduced.

“We can understand the conditions of the tooth flank extremely precisely, so for some of the gears, we could omit the process of creating prototype gears to test the engagement. The fact that we were able to reduce not only job labor but also unnecessary materials is one of the big ever-bettering effects.” (Mr.Shibata)

Of course, the enhancement of the precision of the gear itself contributed to the manufacturing of safer and more fuel-efficient cars. Nikon’s “measuring” technology seems to be a strong advocate for Toyota cars, firmly supporting their reliance from the side.

Gears are important components that transmit the power generated by the automobile’s engine to its wheels. In its development, not only its sufficient durability and efficient energy transmission, but also cutting down the noise of the gears grinding on each other is considered an important factor.

“ We can pursue our ideal manufacturing because they fully answer our expectations with their technology” Yoshikatsu Shibata, Project ManagerFundamental Engineering Dept.Drivetrain Experiment & Analysis Engineering Div. TOYOTA MOTOR CORPORATION

Nikon’s contribution

Enhanced measurement accuracy of the gears, reducing fuel efficiency loss and noise.Factors that link to fuel efficiency loss: energy transmission efficiency, durability, and noise volume, are largely affected by the engagement of the gears. The “Non-contact Sensor 3D Metrology System” developed by Nikon dynamically increased precision using a technology that measures the tooth flank by the “plane” instead of “points and lines,” and realized optimal engagement. Furthermore, measurements that required a long time with conventional technologies could be completed speedily. measurement accuracy of the gears, reducing fuel efficiency loss and noise.

This article comprises the excerpt from Dec. 10, 2016 issue of the Nikkei Business with approval from Nikkei Business Publishing, Inc. No reproduction or republication without written permission

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Two-thirds of Berck’s output goes to the vehicle manufacturing industry in the UK and overseas, of which 40 per cent is bracketry for the engine compartment or wiring loom and the remainder comprises precision contacts for lights, windows, seats and other electrical equipment. The other third of production is delivered to customers manufacturing domestic electrical goods such as cookers, lighting and plugs. Components are stamped using up to 12-stage progression tools on 23 presses, including 12 high-speed models, mainly from coil between 10 and 150 mm wide, 0.1 to 3.5 mm thick. Materials encompass brass including tin-plated varieties, mild and spring steel, copper, beryllium copper, phosphor bronze and aluminium.

The subcontractor has for many years used a Mitutoyo Quick Vision Ace CNC optical coordinate measuring machine (CMM) and a Kemco manual touch-probe CMM to inspect sheet metal parts and tools. The former machine is nearing the end of its useful life, while the latter was recently dismantled as it was beyond

Second-tier supplier of light pressings and small assemblies to the automotive industry, Berck Limited, has invested in a Nikon Metrology iNEXIV VMA-4540 CNC video measuring machine fitted with tactile probing capability. Installed at the subcontractor’s factory in West Bromwich, UK, the multi-sensor machine has greatly speeded the inspection of 2D and 3D sheet metal components, improved measuring accuracy, and facilitated the production of detailed quality reports for customers. It also allows manufacturing processes to be optimised by providing detailed historical measurement data to be compared with current inspection results.

Case study

Pressings subcontractor replaces two CMMs with one video measuring machineOptical inspection time halved and touch probing cycles cut 15-fold

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15News I Volume 12

economical repair. Last year (2015), realising that a new metrology solution would soon be required, Berck’s quality manager Steve Bettridge visited the Advanced Manufacturing Show at the National Exhibition Centre, Birmingham, to investigate what alternatives were available.

He was keen to combine the functions of both the Mitutoyo and Kemco CMMs in one machine and was also aware that 95 per cent of throughput in the quality department at West Bromwich is optical measurement of sheet metal components. Only 5 per cent is touch probing for inspection of components with steep sides, like fuse cups that have a dimensional tolerance of ± 20 µm and are difficult to inspect by optical auto focus. Parts with complex external profiles such as radiator cap inserts are similarly difficult to measure optically. Tactile probing is also employed to assist the in-house toolroom by reverse-engineering inserted press tools, for which no drawings exist, to allow their re-manufacture.

After discarding the idea of combined touch probing and laser scanning on a CMM, as that level of accuracy was not needed for pressed parts and the cost was too high, Mr Bettridge looked at various alternative video measuring machines and decided in favour of the Nikon Metrology iNEXIV. The machine had a larger stage than others on offer, so promised greater versatility use, the company’s proprietary software was considered easy

to use, and the quality of the Nikon camera and objective lens was beyond question. It is noteworthy that, although laser technology has not been adopted, there is the option to fit laser autofocus if the need arises.

The Nikon CNC video measuring machine is equipped with three light sources for efficient inspection, whatever the type of product. Episcopic (overhead), diascopic (transmitted light) and an 8-segment ring LED combine to provide comprehensive illumination and accurate edge detection.

Multi-part measurement speeds optical inspectionSince it was installed in April 2016, the iNEXIV has been a resounding success. Optical measuring routines are programmed conversationally in half the time required using G-code for the Quick Vision Ace. The stage on the Nikon instrument, with its 450 mm x 400 mm working area, is four times the size and the axis movements are considerably faster, so more components can be inspected in a shorter time.

Comparing like with like, the high-speed iNEXIV with its wide field of view and search capability, allowing automatic component recognition and alignment, enables a given number of components to be measured 50 per cent faster than on the Mitutoyo. Moreover, the parts do not have to be all

the same; they can be families of different items arranged in a grid. Provided that the Nikon machine is programmed to inspect the series of components, it measures them all seamlessly and automatically while the operator is deployed elsewhere.

Another advantage of the new inspection facility is its ability to measure folded 3D sheet metal components optically using the instrument’s 200 mm Z-axis stroke, 73.5mm vertical working distance and auto focus capability. The limitation of the other instrument is that its Z-axis is not sufficiently accurate to produce reliable results, so it is necessary to transfer components to an optical projector to determine their depth. Double handling in this way results in a measuring process that is more than twice as long.

Efficient touch-probing of steep-sided components For tactile inspection, the advantages of the CNC iNEXIV over the previous manual touch-probe CMM are even more profound. For a start, the Nikon machine undergoes one 5-minute calibration cycle per week covering the use of all probes. Idle time was considerably longer using the Kemco CMM, as it needed to be calibrated once per day for each probe used.

Formerly, components had to be aligned by hand before each inspection routine could

Steve Bettridge, quality manager of Berck Ltd, with the Nikon Metrology iNEXIV VMA-4540 multi-sensor CNC inspection machine, which includes video measuring and tactile probing capabilities.

NEXIV software displays multiple windows, including of the component feature currently being measured (top left), areas of the sheet metal component being checked for flatness - in this case to 0.1 mm TIR (bottom left), plus current coordinate position, the program being run and the inspection results.

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start. On the Nikon machine, the position of the component is identified automatically to enable the part to be measured with minimal delay. If a changeover between the 2.5 mm ball probe and a star probe is required during the cycle, it is achieved automatically via a Renishaw rack.

Consider, for instance, inspection of 10 of the aforementioned fuse cups. According to Mr Bettridge, it used to take half an hour to complete the job manually, with the attendant risk of damaging the stylus due to human error. Now the process takes a couple of minutes – a 15-fold time reduction – provided that the cycle is already programmed and stored. For such a simple component, it would only take five minutes to program anyway.

Advanced analysis and reporting softwareWith Nikon Metrology’s AutoMeasure software, it is easy to create programs and automatically compare results against CAD models. Deviation of contours can be checked by overlaying digital charts from 2D CAD data onto video images.

The Nikon full-frame colour camera captures highly detailed pictures that are saved to the server at West Bromwich to provide a

reference for future process analyses and troubleshooting. They may also be embedded in customer inspection reports produced by the software. Files of accompanying statistical data are downloaded automatically to an Excel spreadsheet, saving time compared with the previous manual procedure. Many other standardised reporting formats are possible.

Mitutoyo optical programs are currently being edited to run on the Nikon video CMM and about 200 have already been completed. In addition, 50 new programs have been created for the iNEXIV, both for optical and tactile inspection.

Berck uses another Nikon software package, called iNEXIV EDF (Extended Depth of Focus), that allows all-in-focus 3D images of products to be created by stitching together multiple pictures taken at different Z-axis heights. Measurements can then be taken from the resulting composite facsimile for investigation, problem-solving and archiving.

Mr Bettridge concluded, “Nikon engineers came here to provide training within one week of the video CMM being installed. It allowed us to learn how to program the machine and measure our own components, so the training was directly relevant to our business.

“The software is surprisingly easy to pick up, provided that you have a basic knowledge of the principles of metrology. It is also reassuring that Nikon offers software updates for a minimum of 15 years, so our new inspection facility is future-proof.”

Inspection of one of Berck’s single-impression press tools using a star stylus in the Renishaw TP20 probe, which is offset from the optical axis but operates in the same XYZ coordinate system.

iNEXIV EDF software allows 3D images of products to be created by stitching together multiple pictures taken at different Z-axis heights. Measurements can then be taken for investigation, problem-solving and archiving.

17News I Volume 12

Universal, flexible, profitable

Case study

Using Nikon's measuring technology for sub-contract inspection

Measuring prototypes and initial samples on commission is a field of work which requires high-precision measuring technology that can be deployed flexibly and universally for a wide range of measuring tasks. For DIMESS in Winnenden, laser scanners and coordinate measuring machines made by Nikon have proven to be perfect for the job.

“Every day here is full of surprises. When we arrive at work in the morning, we often don’t yet know which measuring technology we’ll be needing, because the commissions we receive are so diverse,” says Frank Sailer, describing his daily work in Winnenden. In March 2012, he took over business from the former company Müller & Emmert GmbH, a specialist for subcontracted measuring work. Together with three employees, he now accepts orders for measuring components for regional engineering companies and car manufacturers, as well as for equipment manufacturers and their suppliers. Generally, the injection moulded or die-cast components he has to inspect, measure and report are initial samples. During the course of batch production, further components are then randomly selected for measurements. In this manner, DIMESS makes a significant contribution to the quality assurance processes of the respective suppliers and manufacturers. The specialists in Winnenden also receive customer orders to inspect metal and plastic prototypes to be used for moulds in tool manufacturing and medical applications.

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Flexibility for a quick succession of different measuring tasksThe components measure anything from a few millimetres to over a metre in length or diameter. Not only do simple features have to be inspected – length, diameter, drilling depth and the location and position of planes, for example – but also complex geometries such as threads, radii, radius transitions and freeform surfaces. Sophisticated 3D metrology is vital in such cases. For this reason, the DIMESS specialists also deploy three CNC coordinate measuring machines (CMMs), each with a measuring volume of around 2000 x 1000 x 800 mm. They are predominantly used in conjunction with 3D touch probes.

“Naturally, we have to be incredibly flexible in order to professionally inspect such a wide range of components. For this purpose, we rely primarily on universal measuring machines,” Seiler emphasises. After completing an apprenticeship with the global market leader for cleaning technology, Alfred Kärcher GmbH in Winnenden, Seiler started working as a Purchasing and Project Manager for an

automotive supplier and manufacturer for precision measuring equipment. Amongst other things, he was responsible for quality assurance processes. As a result, he understands the sometimes contradictory requirements for measuring equipment. Seiler reports that his current company took over two coordinate measuring machines from its predecessor. He then commissioned Nikon to overhaul one of these – a Metris Integra by LK – in order to bring it up to the latest technological standards. Following the retrofit, this can now be used together with the Nikon LC60Dx laser scanner which the company also purchased, in conjunction with Focus software.

Laser scanner for 3D inspection of moulds Particularly when measuring complex plastics, DIMESS now benefits from contactless 3D metrology. “We can now measure complex 3D moulds quickly and easily,” Seiler explains. The data recorded by the laser scanner can be compared directly with the 3D CAD data. On a colour screen, the software clearly shows matches and deviations. Klaus Raddatz, a metrologist at DIMESSS, says

that some of the most impressive features of the Nikon metrology include speed and flexibility. “The laser scanner works on all technical surfaces – whether matt or reflective – without the need for individual calibration. It immediately delivers workable and conclusive measuring data. This means we can use the scanner flexibly for a wide range of metal and plastic components,” he adds. Using this configuration, DIMESS also inspects numerous plastic parts as initial samples for Kärcher, an equipment manufacturer. These components are frequently constructed as freeform surfaces. Some of the injection moulded parts have reflective surfaces, whilst others have a matt finish. Some have solid casing and handles, e.g., made from hard and reflective ABS plastic, whilst others have seals and nozzles made from matt black flexible plastics such as NBR or silicone. Some of the components which have to be measured even combine both types of plastic. Sailer explains, “With the LC60Dx laser scanner by Nikon, we can capture the surfaces and contours of these components with ease. We don’t even have to perform the laborious task of matting the surfaces first. Thus, we have shorter lead times and can be more flexible. Thanks

Complex geometry can be programmed simply and clearly using the CMM manager software by Nikon

“ In order to measure and document initial samples of injection-moulded parts, we require universal, flexible and economically efficient measuring technology,”Frank Sailer of DIMESS in Winnenden

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to the outstanding features and functions offered by the laser scanner, DIMESS was able, for example, to capture the position and geometry of threaded bushes on a connector housing in the shortest possible time, and compare the results with the nominal 3D CAD data. Touch probes were not suitable for this measuring task. A high level of flexibility is also guaranteed by the fact that the Nikon laser scanner can also be used easily on the other coordinate measuring machines at DIMESS. In particular, this applies to their most recent acquisition, an ALTERA 20.10.8. coordinate measuring machine from Nikon. Sailer reports, “We were totally satisfied with the support offered by Nikon for upgrading our LK measuring machine. A few months ago, we required a third coordinate measuring machine in order to increase our capacities. Nikon was naturally our first choice for this investment, thanks to our extremely positive experience with the company.”

Superior performance and value for money For Sailer, another factor played a major role in this investment: “Nowadays, precision is regarded as a matter of course. With regard to highest engineering quality and precision,

measuring technology made by Nikon is second to none. However, when taking measurements on commission, we also have to consider costs, because the competition is strong.” The metrologists working at DIMESS confirm that Nikon Metrology CMMs offer the perfect balance between precision, reliability and value for money. “Nikon offers the best cost/benefit ratio for economic investment and quality performance,” The ALTERA 20.10.8 is primarily used in conjunction with measuring probes. One of the main advantages for metrologist Raddatz is the CMM-Manager software by Nikon. “The interface for this software is very user-friendly. This makes the coordinate measuring equipment extremely easy to use and programme. This even applies to very difficult measuring processes for the complex geometric shapes we frequently encounter in moulds and tools.” Sailer emphasises that the software can be mastered within a very short space of time thanks to its clear and unambiguous structure. “It only takes a couple of days to learn how to use it productively,” he adds.

Qualified customer serviceSailer is also impressed with the customer service offered by Nikon. Competent support is always available immediately, he affirms. The Nikon experts know the user’s situation, and can accurately assess the level of existing expertise. As a result, they can offer programmers and users qualified support to enable these to find quick, practical solutions for their various measuring tasks. One aspect which both Raddatz and Sailer particularly appreciate is the fact that they can always rely on support from the same contact person. “Particularly in the field of measuring commissions, it’s important to get an immediate and correct answer to any questions that arise regarding measuring strategies, programming of coordinate measuring machines or how to use the software. Our experience has shown that Nikon is able to provide such service. So we have no problem in unreservedly recommending measuring technology” Sailer concludes.

Flexible and for all purposes: The Nikon laser scanners can be used in conjunction with various coordinate measuring machines, and quickly capture complex 3D structures regardless of whether the components are hard or soft, and have a matt or glossy surface.

Frank Sailer: “Nikon not only offers quality measuring technology, but also competent service from experienced and qualified metrologists.”

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The Indian based worldwide needle exporter, Quality Needles is using the fast, high accuracy Nikon Metrology LC15Dx CMM laser scanner for inspection of in-house manufactured production tools. With the advanced inspection equipment, Quality Needles recover costs from the initial out lay within one year.

Case study

Accelerated inspection cycles help Quality Needles recover investment cost within one year

Incorporated in 1984, Quality Needles (Noida, India) is one of the world’s leading medical needle producers and specializes in the manufacture of surgical suture needles. High standards and strict quality assurance are of the utmost importance, as the needles need to conform to worldwide quality standards such as to IS-9165: Bureau of Indian Standards, German Vornorm DIN-13170 and more. It’s not just a large quantity of needles produced, but a wide variety also, with over 2,500 different types and sizes of regular eye, spring eye, drilled end and atraumatic needles. The company currently exports 80 % of its production across Europe, Asia, the Americas and Africa for use in a whole scope of procedures from ophthalmic to cardio-vascular surgery.

To meet the quality standards it conforms to, Quality Needles excels in its quality control processes. For the

production of the needles, there are tests for sharpness, stiffness, ductility and many others, however it’s not just the quality of the needle that is monitored so closely. The success at Quality Needles is largely attributed to the in-house development of its own equipment, tools and technology. For some of the vital machining components in the production of these needles, other tooling suppliers were unable to guarantee the levels of quality required or were simply too costly. It was discovered that for Quality Needles to produce these components in-house would lead to significant savings. Whilst the production of these components wasn’t an issue, a well-trusted, comprehensive and accurate quality assurance method needed to be introduced. Quality Needles turned to Nikon Metrology to offer a solution that could not only increase productivity, but introduce an unparalleled level of accuracy.

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Increased level of production requires a fast and accurate solution. Anchan Mago, the General Manager at Quality Needles explains how he discovered that vast savings could be made by manufacturing the production components with the in-house facilities rather than using expensive imports. The feed wheel, made from EN-31 carbon alloy steel, is a very important part in the manufacturing process at Quality Needles. It is used to transport needles from station to station throughout the manufacturing process. It features grooves that vary in size, typically between 0.20 mm and 0.90 mm to carry the needles. Whilst it is a basic component in all the machines, its accuracy and concentricity is very important for functionality of the machines, so to be in full control of the component dimensional quality is paramount.

Having recently upgraded the production facilities, Quality Needles has seen an enormous increase in its production capabilities. Since the introduction of the new 5-axis CNC machine center, the previous manual measurement methods couldn’t cope with the increased throughput. Callipers, micrometres and other manual techniques were previously used to monitor the quality of these pivotal components. The higher level of productivity meant that they required a faster measurement method. Not only were the manual methods considerably slow, but due to operator handling, they offered limited repeatability.

A rigorous benchmark for selecting the laser scanner. Quality Needles needed a solution that was accurate and reliable enough to check the profile, straightness, dimensions and concentricity of these vital components but also fast enough to deal with the pressure of high productivity requirements. Prior to searching for the solution, criteria were outlined which consisted of achieving accurate surface measurements and profiles of parts, as well as speed to complement the improved production capacity of the new CNC machines. A feed wheel like the one pictured was used as a test piece to determine if the laser scanners were capable of measuring the surfaces and features required.

A variety of other CMM manufacturers were consulted but it was found that no solution could meet the tough requirements other than the Nikon Metrology LC15Dx. The angles of the grooves in the feed wheel were too tight for the other laser scanners to measure and grooves often weren’t detected, however for the LC15Dx this wasn’t an issue.

With the unique ESP3 technology and a probing error of just 1.9 µm (comparable to tactile probing accuracy), the LC15Dx offers the best accuracy for a laser scanner. The Enhanced Sensor Performance (ESP3) technology maintains accuracy, speed and data quality by intelligently adapting the laser settings for each measured point in real-time, necessary to cope with the glossy metals and varying part reflections. The fact that Nikon offered the perfect pair; the ALTERA and LC15Dx to introduce a multi-sensor system left Quality Needles with no doubt about which system to select. The out coming point clouds are compared to original CAD models and colored deviation plots indicate where errors occur. Anchan explained that the superior insight into product conformity helps Quality Needles to manufacture the intricate

components with ease and speed. Beside the LC15Dx , the systems is also equipped with an SP25 scanning probe, mainly to measure inner diameters of the wheels.

An increase in productivity and quality output have helped to recover costs within a year.In less than a year, the original outlay for the CMM and laser scanner had been recovered with the vast increase in overall productivity and product quality, enabling a much higher work capacity. Anchan was very complementary of the Nikon solution and outlined the main short term benefits they have profited from already. With a part that was previously difficult to measure, it was a big step forward to be able to inspect it, but the LC15Dx does so with such ease, Quality Needles has seen its productivity rise significantly. Anchan states that Quality Needles has seen an increase in productivity by 3.10 % and the overall quality performance indicators have also improved by 1.6 %. Considering that Quality Needles work on 110 million cycles per month using the wheels in question, these figures are quite appreciable.

“ The LC15Dx offers a superior insight, which results in the ability to manufacture complicated parts much more easily. Anchan Mago – GM at Quality Needles.

The high resolution LC15Dx accurately measures the narrow grooves of the feed wheel.

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Non-renewable energy resources are used to generate approximately 85% of the world’s energy today, but the issues with these finite sources have been known for a long time. It’s not just that the supplies of fossil fuels are exhaustible and will one day be depleted but also the effect that using them has on the world. With greenhouse gases such as carbon dioxide created by burning fossil fuels contributing to global warming, we need to find alternative resources to power the world. Taking into consideration the limited reserves and the negative environmental impact of non-renewable energy resources, DTU Energy’s primary objective is to develop technologies for conversion and storage of energy, in sustainable energy systems.

In 2012, a part of the Danish national lab, Risø with over 20 years of experience in fuel cell development merged with DTU to become the department DTU Energy. The dedicated department focuses on education, research and development of functional materials and their application within sustainable energy technologies. Recognizing that with sustainable energy systems of the future, sources such as solar and wind power will fluctuate, it is vital to be able to efficiently convert and store the energy as needed. Researchers in the department work on technologies and materials for efficient conversion (e.g. fuel cells, thermos-electric cells and solar cells) and subsequent storage of different forms of energy (e.g. batteries and electrolysis cells). An example of this is that wind power may be stored by converting electricity into a fuel such as hydrogen or a hydrocarbon which can then be stored.

CT provides insight which cannot be obtained from 2D images The Department of Energy Conversion and Storage has state-of-the-art laboratories with experimental facilities and continue to invest in the best equipment for their projects. Current imaging methods included electron microscopy (SEM, TEM), FIB-tomography, TOF-SIMS, XPS, neutron imaging, scanning probe microscopy and diffraction tomography. However, for material research DTU

DTU use a high flux Nikon Metrology CT system to non-destructively investigate energy materials such as batteries and fuel cells. The high energy 225kV microfocus source penetrates dense battery, electrolysis cell and fuel cell samples in the search for suitable materials to develop sustainable, green energy systems.

Case study DTU Energy uses industrial CT to research the development of green energy solutions

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required a CT system capable of delivering insight into the often complex 3D structures characteristic of most energy conversion and storage devises.

The complex 3D structure in batteries or in the different types of electrochemical cells can be difficult to analyse from 2D images alone. For most characterisation methods, it is necessary to break or cut the materials to investigate the internal parts. With CT, it is on the contrary possible to investigate the devices in 3D non-destructively. This for example gives access to information about connectivity of pores or other parts in the devices, information which cannot be obtained from 2D images alone. The Nikon CT solutions are able to provide a valuable insight into the internal surfaces and material structure, without causing damage to the materials.

The XT H 225 ST is the extended model from Nikon Metrology which allows for samples up to 50 kg in weight and 300 mm in diameter to be scanned. The extra size and weight capacity is what DTU needed to scan heavier and larger samples such as solar, fuel and electrolysis cells. DTU selected a 16-bit PerkinElmer 1620 flat panel to obtain high-definition images. The source of XT H 225 ST is also equipped with a multi-metal target that generates the specific X-ray spectra. Beside the standard tungsten target, the operator can select 3 other materials

in the target: silver (Ag), molybdenum (Mo) and copper (Cu). For some material analysis, it is often better to have the X-ray emission at lower energies, this can be achieved by using different materials as a target.

DTU required a multi-metal target due to the potential frequent usage between a variety of different departments. The wide scope of options available with the Nikon Metrology systems makes it the most flexible tool for quality laboratories, production facilities and research departments.

The system has so far been used to provide very useful information about pore fraction, pore shape and connectivity as well as interface areas between two materials and particle sizes. Another example is to investigate the internal 3D structure of batteries to track possible changes during or after aging cycles of the batteries.

Motorized FID reduces scan timeWith over 25 years of expertise, the CT specialists at Nikon Metrology have developed and manufactured complete systems, incorporating proprietary micro-focus X-ray sources, high precision 5-axis fully programmable manipulators and fast acquisition and reconstruction software. The XT H 225 ST model comes with a motorized FID (Focal spot to Imager Distance), meaning that

the detector can be moved closer to the source. A shorter FID means that the X-ray flux is increased and with a shorter imager exposure, the scan time can be reduced. DTU have made use of the high flux of the ST model to facilitate faster scans for in-situ measurements.

Søren Bredmose Simonsen – Researcher at DTU, explained that the high energy 225kV microfocus source was the main reason for selecting the Nikon system. “The motivation for buying the Nikon system was the high energy source that was able to scan materials with heavier elements and larger samples such as batteries, solar cells and a fuel/electrolysis cells”. With up to 225kV and a minimum spot size of 3 µm, the 225kV microfocus source is able to cope with a range of sample sizes and densities.

The XT H 225 ST scanner is part of DTUs new 3D imaging center which is currently being established by DTU Energy, DTU Compute, DTU Mechanics and DTU Physics. The center is focusing both on academic research and also on research and development projects in collaboration with industry. Examples are CINEMA (allianCe for ImagiNg and Modelling of Energy Applications) and LINX (Linking Industry to Neutrons and X-rays) which are projects that combine academic and industrial research.

Søren Bredmose Simonsen fixes the lithium iron phosphate battery in position before investigating with X-ray CT.

Internal parts of a cylindrical lithium iron phosphate battery investigated with X-ray CT. Left: Radiogram of the entire battery. Right: 2D slices in the reconstructed 3D volume of a small volume at the centre for the battery.

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An important challenge to manufacturers is to increase product quality, which can be achieved through 100% part inspection. Traditionally, X-ray Computed Tomography (CT) has been a valuable tool mainly used in research or prototyping labs to evaluate failures or spot defects; a proven engineering tool that was generally considered as too slow to be used on a production line.

That is, until now! Recent advances in high-flux rotating targets for X-ray sources, coupled with easy automation of CT scanning and analysis techniques allow samples to be scanned, reconstructed and evaluated in time measured in minutes with micron accuracy. This opens the gate to a broad span of automation inspection applications, varying from simple pass/fail inspection to full in-line automated CT inspection with feedback to the production process.

Automated CTFull control of your production process

Automated CTFull control of your production process

Automated routines ensure consistencyIn failure analysis or quality control laboratories where batches of samples need inspecting, Nikon Metrology CT systems are designed with automation in mind.

As standard, Nikon Inspect-X software allows users to save scan profiles which can be recalled at a later date. The CT scan profiles define the parameters for the X-ray conditions, manipulator position and imaging settings, along with reconstruction and volume analysis parameters. This ensures repeatability of

the complete CT process by eliminating the need for parameter selection by operators.

Reducing operator involvementIn a production environment where fast inspection tact-time is required, semi-automated CT inspection systems are a solution that leave only one manual task involved with CT inspection; part handling. Parts can be loaded by the operator individually or as a rack of multiple parts that are loaded individually to the CT scan position by an internal loading system.

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Industry 4.0: Smart manufacturing for the future by automation and data exchange.

Within a smart factory manufacturing systems communicate and cooperate with one another and humans. Technology is used to monitor system status and perform corrective actions using decentralized decision making. In-line measurement provides immediate feedback, enabling optimisation of the manufacturing process in real-time. Supply chains benefit from superior cost efficiencies, better quality products and higher productivity.

The smart factory

Improve quality

Reduce costs Increase productivity

$ $$ $

Automation benefits

Centralized data

Deskill complex tasks

Closed-loop manufacturing

Mechanization water power, steam power

Mass production, assembly line,

electricity

Computer and automation

Cyber Physical Systems

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By communicating with production databases the CT system can automatically recognize the part to be inspected, and adjust all parameters accordingly, further removing possible operator error. Inspection results can be written back to the database for further analysis or to preserve data history.

100% part inspectionThe in-line CT inspection system is a solution for fully automated production environments

where critical parts with complex internal geometries or material structures need to be inspected. As such this is the ideal inspection solution for companies that implement “Industry 4.0” methodology on the shop floor.

With no user input the complete CT inspection process is automated; part identification codes are scanned and handled though the database and robots load/unload from conveyors and position parts in the CT

system via an automated door. The part is then automatically scanned, analyzed and sentenced according to the database recipe.

The entire process can be completed in under a minute, with possibility to scan multiple parts at once to further increase tact-time. For longer tact-times scanning and analysis of parts can occur in parallel.

CT scanning CT reconstrution & analysis Pass / Fail analysis

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Nikon swiftly integrates customer-specific measuring and inspection processes

Flexibly expanded

WESO-Aurorahütte, an iron foundry based in Gladenbach, produces high quality brake discs for rail vehicles. Once the cast parts have been machined, numerous geometric features need to be measured, correlated and evaluated statistically. This can now be done effortlessly with measuring software which Nikon has modified according to the foundry’s specifications.

Case study

“By moving into the field of railway engineering, we’ve entered a new market which will safeguard the future of our company,” reports Alexander Tonn proudly. He heads the Certification and Quality Control department of the WESO-Aurorahütte GmbH iron foundry in Gladenbach. However, various hurdles had to be crossed to achieve this goal. The foundry, which belongs to the Viessmann Group, formerly focussed on supplying a wide range of cast iron parts for boilers to Viessmann, a central heating manufacturer. In addition, the Gladenbach-based foundry manufactures cast iron parts for mechanical engineering, agricultural engineering, pumps, gearboxes, engines, valves and cooling units. The batches vary in size from 1500 to 50,000 components per annum. On its automated moulding and casting lines – with moulds measuring 900 x 1100 x 200mm – the company can produce parts weighing up to 150kg. “As a result of technological progress, the demand for cast-iron boilers has declined,”

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Tonn reports on the trend in central heating since the 1990s. Today, boilers used for central heating in residential properties are small and lightweight, and generally made of sheet metal which is remodelled and welded. As a result, the foundry in Gladenbach is receiving fewer orders from this industry. However, the company nonetheless wishes to continue using its full capacity of around 30000 tonnes per annum, and safeguard the 400 workplaces in the foundry. “Our foundry specialises in producing small and medium-size batches of cast-iron components with cones, bridges, domes and perforations,” Tonn reports. The search for suitable components finally led to brake discs for rail vehicles. “Due to their size, we can produce these components efficiently and well on our existing moulding lines. So they’re an ideal addition to our portfolio. In addition, the batch sizes ordered by the brake and vehicle manufacturers correspond exactly to our capacities. So we seized the opportunity,” Tonn adds.

Value creationHowever, the brake discs require considerably more machine cutting than boiler components. For example, numerous cones, domes and bridges have to be overwound on interrupted cuts for ventilated axle-mounted brake discs and single-piece wheel brake discs. Numerous holes, counterbores, screw threads, grooves and perforations also need to be finished. The foundry in Gladenbach has invested in the heavy machining and processing equipment required for this purpose. “Our clients prefer to receive finished components which are completely ready to install. By investing in suitable manufacturing technology, we add

significantly to the value of what we produce. We also have extensive expertise along the entire manufacturing chain, from the casting process through to machine cutting. This gives us an edge over our competitors,” Tonn says, explaining the company’s strategy. WESO is even able to offer surface coating and assemble the moulded and processed components.

As the foundry in Gladenbach has observed, railway engineering clients and supervisory authorities and institutes demand comprehensive quality controls. These are necessary to ensure a high level of safety when the brake discs are used in locomotives, freight cars, passenger trains and trams. Hence the foundry in Gladenbach has to repeatedly furnish evidence for machine capability and process stability. For this purpose, WESO-Aurorahütte uses Nikon’s LK V coordinate measuring equipment. This is installed in a spacious, temperature-controlled measuring laboratory. Cast-iron parts weighing up to 150kg and measuring up to 1200mm x 2000mm x 980mm can be measured here with ease.

Statistical evaluation However, the requirements regarding the brake disc features which have to be measured are particularly challenging. André Schneider, who is responsible for quality control in the measuring lab, explains. “Besides the diameters of holes, the depth of counterbores, the thickness and the overall diameter of the brake discs, we have to determine the positions of the holes and grooves, their positions relative to each other,

and their positions relative to a virtual central axis. I say virtual, because the brake discs have a large hole in the centre so that you can push them over the gear wheel shaft. This means we can only determine the position of the central reference axis by evaluating other measurements.”

The metrologists in Gladenbach were able to measure some of the relevant features using coordinate measuring equipment in combination with Nikon’s CAMIO measurement software. However, it was difficult – and impossible – to determine correlations between features such as the symmetry of holes and milled grooves in relation to the central axis of the brake discs. On the one hand, this concerns the pitch circle diameter, and on the other hand the angular position of the six or eight holes and grooves. These measurements not only serve to ensure each brake disc is manufactured with precision and to high quality standards, but also to assess machine capability for the machine cutting. For the latter purpose, the recorded measurements had to be transferred to a database and evaluated statistically using dedicated analysis and reporting software.

Software swiftly customised To rectify this situation, the foundry metrologists contacted the specialists at Nikon. Within a matter of weeks, a suitable solution was found. The experts first adapted existing measuring cycles and the inspection algorithms to evaluate the results with the required correlations. They then programmed a data interface which was able to present the required measurements in a standardised form

“ With cast brake discs for rail vehicles, our foundry has been able to gain a foothold in a new and profitable market. Alexander Tonn, head of the Certification and Operative Quality Control department at WESO-Aurorahütte GmbH in Gladenbach

The WESO-Aurorahütte foundry produces up to 100,000 brake discs per annum in around 80 versions

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for the required statistical evaluation. Working together with Schneider, the experts then used real customer samples in Nikon’s training centre to develop suitable measurement methods and strategies for the cast components. As a result, staff in the quality control department of the foundry now only need a small number of individual measurement cycles on the coordinate measuring machine to record the required features of the holes and grooves, such as their relative angular positions and their position relative to the virtual central axis. The readings are transferred directly to a standardised database where they are then evaluated statistically. The results indicate the machining capability and stability of the processes. The evaluated data can also be

used as documentary evidence. Schneider reports that he was fully satisfied with the collaboration with Nikon and with the resulting software update. “The programmers and service technicians collaborated closely with us and were quick to identify our special measuring needs,” he emphasises. To summarise, Tonn adds: “In a matter of weeks, the metrology experts at Nikon were able to develop workable routines for measuring and evaluation. We were able to optimise these together in an ongoing process. The result, in a little less than three months, was an extremely efficient software update to CAMIO 8.2. We are totally satisfied with the way this works, and it meets all of our specific requirements. Using this software, we can now effortlessly

furnish evidence of the quality of the brake discs which are cast and machine cut in our foundry, in accordance with all specifications. Nikon’s qualified and swift service, based on their extensive metrological expertise, contributed significantly to our success. We can now hold our own as a serious competitor on the exacting market for railway technology.” The foundry in Gladenbach uses the updated and modified CAMIO 8.2 software on the coordinate measuring machine to measure and evaluate individual cast components at the beginning of different production runs. It is also now able to swiftly and effortlessly generate statistical evidence on machine capability and process safety.

News I Volume 12

Within just a few weeks, metrology experts from Nikon modified the CAMIO software for the LK V coordinate measuring machine in order to provide reliable and fast readings for the angular position of grooves and mounting holes

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Industry leader Mindarika based in India, designs, develops and manufactures all kinds of electrical switches and safety devices for automotive OEMs. Requiring a non-destructive inspection method, Mindarika install the Nikon Metrology XT H 225 ST to introduce non-destructive testing for an increased insight to maintain customer satisfaction and high levels of quality.

Case study

Mindarika adopts microfocus CT to inspect automotive components

Mindarika is a joint venture between Indian company Minda Industries and Tokai Rika, a Japanese company. Minda Industries, sought the expertise in intelligent transport technologies and safety/security devices for automobiles that Tokai Rika were renowned for, forming Mindarika in 1992.

India is one of the world’s largest motor vehicle manufacturers in the world with nearly 4.6 million vehicles produced annually. By the year 2020, it is estimated that 450 million vehicles will be on the road in India. Today Mindarika holds a 47% market share and is the market and technology leader of automotive switches in India. It is the supplier to all OEMs in the 4-wheeled and commercial vehicles segment with major customers that include Honda, Nissan and Ford, TATA,

Maruti Suzuki India Ltd. (MSIL) and Toyota plus many more. With over 1.000 employees harbouring a vast amount of knowledge and innovation, Mindarika designs, develops and manufactures all kinds of electrical switches to be used in vehicles.

To stay ahead of competitors, the industry leader must continuously develop new products with superior quality at a fast rate. The majority of the parts, panels and switches manufactured by Mindarika mainly consist of plastics and electronic components and are found in vehicles worldwide. Parts such as manual, semi-automatic and automatic HVAC control systems, power window switches and lever combination switches make up a large percentage of the items the Interior, Controls & Safety (ICS) domain deal with.

Product quality and customer satisfaction are the priority.Mindarika has consistently received awards for the quality, efficiency and innovation of its products. These include twice being awarded the “Energy Conservation Award” from Bureau of Energy Efficiency, the “Gold Medal from ACMA for Overall Excellence in Manufacturing” twice and the “Safety and Environmental Award” from Haryana Labour Department amongst many more. Mindarika says that “Such recognition from leading professional institutions is an affirmation that we pull out all the stops for the best products possible, as per the customer needs, priorities and expectations”.

As a company that prides itself on customer satisfaction and high quality standards, it

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was recognized that Mindarika was ready to upgrade its inspection facilities. The previous destructive methods offered limited repeatability, low level insight and often lead to wasted materials and time. Amit Mishra - Deputy Manager at Mindarika explained that for continuous improvement and to maintain the growth the ICS domain had already shown, investment in the latest inspecting technology was required.

Needing a non-destructive inspection method with fast turnaround timesThe ICS domain contributes a substantial percentage of revenue to the group sales and as such, Mindarika knew it was vital to continuously improve, by upgrading its facilities. It was agreed that a non-destructive testing solution was required to help improve the Quality Assurance department. After the decision was made that a CT system was the equipment required, Mindarika consulted a variety of vendors. With a range of new parts being introduced, a system that was able to analyse internal structures and geometrical alignment with a profound insight was required. For all vendors they consulted, it was paramount for the company to be able to deliver and install the system within four months.

Amit explained that the assembly alignment and perfectly functioning electrical connections are vital for long life operation. To decide on the best solution, a benchmarking test

was used based on existing reports from the sample. The results of these tests concluded that the microfocus Nikon Metrology XT H 225 ST offered the best image quality and as such the most profound insight into the components. With the delivery and installation in the desired time frame, Mindarika had no doubt that the Nikon CT system was the ideal solution.

Exploring the full potential of the XT H 225 STAmit explained that the increased level of insight that the Nikon solution provides a level of trust in the components that wasn’t achievable before using destructive methods. The improved insight into the conformity of the products leads to faster diagnosis and troubleshooting, improving the efficiency of the QA department. The 225kV micro-focus source that is used at Mindarika, is able to deal with a wide range of materials and varying densities. It also enables detailed capture and measurement of internal features, vital for quality control and failure analysis. The XT H 225 ST system is the most flexible system, ideal for quality labs and production facilities with its ability to penetrate a wide range of materials and densities as well as containing sample sizes up to 300 mm in diameter and 50 kg in weight. For Mindarika this solution is perfect as the products they produce vary greatly in size.

Following the installation of the Nikon Metrology system, the QA team at Mindarika

have expressed their delight at the capabilities of the system. Amit explained that the system has so many features and capabilities, that as successful as the system has been thus far, they are still only exploring the full potential. He continued to state that with faster insights into product conformity, the department has seen an improvement in its productivity due to the flexibility of the system, the QA department acts as a central NDT hub and provide X-ray consultancy for the other domains and associate companies.

Examples of plastic electronic switches and a lever combination switch prior to inspection.

The screen shows live images of a lever combination switch and its internal features.

32

Livnica Preciznih Odlivaka (LPO) was founded in 1978 and is based in the city of Ada, Serbia. LPO is an expert in vacuum and air castings of super-alloys and stainless steels for applications such as turbine blades, diffusers and other complex aerospace parts. LPO currently holds certificates for quality regulations including casting of jet engine parts, and special processes including heat treatment, Ni-based castings and mechanic material testing.

LPO has been a customer with Nikon Metrology for over 10 years, originally using the LK INTEGRA CMM for its Quality Assurance needs. Due to a recent surge in business activity, LPO decided to expand by introducing a new production hall to capitalise on the demand for its expertise. However, due to the increase in production capacity, its original, solitary LK CMM has taken on double shifts, working at full capacity to keep up with the booming workload.

It was recognised that LPO needed to invest in a new quality assurance tool to share the workload, to complement the increased production capacity and to maintain its renowned high quality standards. Miloš Dojcinovic in the Purchasing department worked closely with the CMM operators in the decision process to understand what was required of the new system.

Vacuum casting super-alloys for aerospace componentsVacuum casting is a way in which metal casters can achieve optimal properties for cast components as well as successfully produce difficult, complex castings such as turbine blades and diffusers. By using a vacuum to draw the molten metal into the mould, the process can be accurately and closely controlled. This process offers an improved quality and finish to the final casting as well as excellent dimensional tolerances compared to pouring.

The turbine blades and diffusers produced by LPO are typically NiCo (Nickel/Cobalt) based alloys, formed through the vacuum casting process. Super-alloys are ideal for aerospace turbine components because of their key characteristics – excellent strength and resistance to heat and corrosion which is vital when considering the

Already using a LK bridge CMM for measurement and geometric inspection of aerospace components, LPO invests in a second Nikon CMM system to cope with the additional business and to increase production capacity.

Case study

Precision meets productivity for aerospace component inspection

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33News I Volume 12

temperatures and pressures these components will be subject to.

When producing these components, there is no room for error as any inaccuracies in geometry or positioning can lead to poor energy conversion efficiency, loss of aerodynamics and in extreme cases, complete failure. Therefore, it is paramount for manufacturers of aerospace components to have a thorough and comprehensive Quality Assurance department using the most adequate technology available.

Extended production capacity requires a fast & accurate QA systemHaving noticed a significant increase in the demand for its expertise, LPO recognised the opportunity to expand and grow as a business. The precision casting plant in Ada was working at maximum capacity and it was a natural decision to open up a new production hall. To complement this new and increased production capacity, the Quality Assurance and Dimensional Inspection department was also in need of a revamp.

LPO needs to maintain its consistent high quality as well as support the new facility’s increase in throughput. Miloš worked in close collaboration with the CMM operators

and analysis led to a step up in size of CMM. Thorough research was conducted prior to selecting the new inspection solution. Both Zeiss and Hexagon were consulted to see which other solutions could match the expectations.

User-friendly CAMIO interface makes Nikon the ideal solutionMiloš explains, “The operators who originally use the LK INTEGRA prefer the versatility and no-nonsense programmability of the CAMIO software and CAD based part programming. They also aim for the continuity and correct compliance to DMIS standard”.

The combination of experience using Nikon systems, the user friendly interface with CAMIO software as well as a good working relationship with the company made the Nikon solution the number one choice. With requirements for the new system being quite similar to the original parameters for the LK INTEGRA, LPO already knew what Nikon CMMs are capable of. The investment in a Nikon CMM with ceramic frame comes with a 10-year structural warranty, meant to achieve and maintain original specified accuracies for the extended working life of the Nikon and LK CMMs.

Achieving 100% inspection with the Nikon ALTERAThe selected CMM was the 15.10.8 ceramic bridge ALTERA, with TP20 tactile probe and the CAMIO8 software package. Since the installation and training with the new system, Miloš discussed some of the benefits they have seen so far.

Miloš explains how the speed of measurement on the new system is a major benefit for the new facility. On the ALTERA CMM, 100% inspection can now be achieved, to absolutely guarantee individual component conformity. LPO typically conducts plane-line-point measurement of the turbine blades, diffusers (pictured) and other aerospace components, according to customer requirements. With CAMIO, LPO has a better understanding of product conformity with full 3D part-to-CAD comparison and inspection data is easily shared with the click of a mouse. The reports can be exported in various formats to fit each client’s individual needs for data interpretation in a QA department.

Miloš adds, that with the ALTERA CMM, they are now multi-sensor ready. Whilst already achieving 100% inspection, if ever the need for multi-sensor technology arises, then LPO is perfectly positioned for a Nikon Metrology Laser Scanning upgrade.

Casted NiCo alloy diffuser for an APU (auxillary power unit) during inspection.

The digital model of the NiCo APU diffser, pictured left.

“ With the new Nikon ALTERA, we can achieve 100% inspection and are multi-sensor ready for any potential upgrades in the future Miloš Dojcinovic - LPO Puchasing.

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Established in 2002, Saline Lectronics is an electronics contract manufacturer based in Saline, Michigan, US. Lectronics consists of a talented and experienced team of electrical, mechanical, test and quality engineers, offering comprehensive assembly and manufacturing support for products. The aim for Saline Lectronics is to solve the most complex and technical challenges for its customers.

Guaranteeing continuous product performanceAs Lectronics’ customers continue to design highly-complex, extremely dense circuit board assemblies, it’s crucial that both Lectronics’ manufacturing technicians and engineers can properly inspect and guarantee the manufacturing quality of those products.

In order to guarantee a product’s performance throughout its entire lifecycle, you need to see and analyze the connection of hidden solder joints underneath bottom-terminated components. Traditionally, the electronics manufacturing industry has relied on manual visual inspection, or 2D X-ray systems, to determine whether or not a connection is acceptable. Unfortunately, both of these methods are highly unreliable and completely subjective. It’s been shown that without an accurate picture of what’s going on underneath the component packages, technicians won’t always agree on what constitutes an appropriate solder joint. To remove the subjectivity of measuring accurate connections in leadless components, Saline Lectronics recently invested in a Nikon XT V 160 with

a Varian 1313Dx flat panel detector and X.Tract technology. Upgrading from a 2D X-ray system, this new, high-quality PCB inspection system will allow Lectronics’ technicians to get inside, underneath, and a highly magnified look at component connections for complex printed circuit board assemblies (PCBAs).

Nikon XT V exposes hidden features“Our old machine was simply an X-ray,” commented Scott Sober, VP of Operations and Manufacturing at Lectronics. “The Nikon XT V is a proper inspection tool. With it, I will definitively know that my manufacturing process is providing excellent results for all bottom-terminated components.” The Nikon XT V 160 will expose any hidden features allowing further examination into BGAs and other array style package as well as inspect heels of solder joints, fine pitch packages, and internal characteristics of solder joints. With a proprietary NanoTech 160kV X-ray spot and electromagnetic lens, this system offers the latest digital imaging technology available and produces clear, sharp images at the micron level.

Saline Lectronics, USA is an electronics contract manufacturer, offering to solve the most complex technical challenges with its impeccable quality standards. Up to date with the latest technological advancements and using the latest manufacturing equipment, Lectronics invests in the Nikon XT V 160.

Case study

Revolutionizing defect analysis for electronic components

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35News I Volume 12

This Nikon XT V 160 will also serve as an excellent process development tool for Lectronics. Getting clear pictures of specific areas on a PCBA that were not previously seen on Lectronics’ older X-ray, will help to reveal any hidden, unknown defects. With defects being brought to light sooner in the assembly process, Lectronics’ manufacturing team will be able to engage in root-cause analysis, and update production procedures in order to prevent the defects from re-occurring.

Automated X-ray inspection helps to save timeWith the automated inspection mode feature on the Nikon XT V 160, Lectronics will be able to program a variety of “routines” into the system that will function as batch Automated X-ray Inspection (AXI). These routines will automatically inspect a certain PCBA, or area of components on the PCB, and perform a full 2D and 3D analysis of the region of interest. This will enable Lectronics’ technicians to quickly and intuitively run routines of repeated inspections for production circuit board assemblies. Running routines will help Lectronics’ team save time on first time build assemblies as well as during the troubleshooting process of any production fall-out. The Intelligent Program Control feature on the X-ray allows for customizable system control, which makes setting up the camera for each PCBA seamless and quick.

Unprecedented magnified view with X.Tract“We chose the Nikon system because of the X.Tract software,” commented Jason Sciberras, Lectronics Manufacturing Manager. “The laminography technology gives us an

unprecedented, magnified view of any ball underneath a BGA. Even if the BGA has 2,000 balls, I can examine each one individually from any angle. This technology will completely revolutionize how we measure appropriate connections.”

X.Tract works by taking 2D images at the submicron level 360 degrees around the PCBA or component of interest. Those sliced, 2D images are then reconstructed into a detailed 3D model that can be analyzed on any plane with the X.Tract analysis tool. The highly magnified 3D image will give Lectronics’ technicians insight into defects that are typically obscured in standard 2D X-ray systems such as head-on-pillow (HoP), open solder joints and cracks. Additionally, X.Tract helps to isolate views of the different layers of complex component packages such as package-on-package (PoP) or multi-chip modules.

Non-destructive testing saves clients’ moneyThe enhanced visual inspection of the Nikon X-ray system will afford in-depth analysis during troubleshooting that will be enormously beneficial to Lectronics’ test engineers. In previous cases of unknown test failures, if the board had a micro-BGA or QFN, the PCBA may be sent out for cross-sectioning and destructive testing to best determine root cause. By being able to examine these components in-house, without destroying the PCBA, Lectronics will not only guarantee a faster resolution to test fall-out, but also save clients precious time and money. The 3D X-ray technology will also be incredibly beneficial for Lectronics’ mechanical assembly technicians as they assemble and complete different types of box build products.

Of all the different products that Lectronics assembles, electro-mechanical builds make up about 40% of the total business. With this new 3D X-ray analysis, technicians will be able to see inside closed box build units to guarantee that everything is sitting correctly inside of the unit. The X-ray system will prove that components are not put under any additional stress after mechanical assembly is finalized.

Clear pass/fail reporting with Inspect-XThe Inspect-X feature provides a full, real-time, automated reporting system that details the X-ray system’s inspection results. Reports are fully customizable and will detail the analyzed results of the specific components that were inspected with both 2D and 3D images of the solder connections underneath analyzed components. The Inspect-X reports will also clearly define passed and failed components with quantifiable data to support those determinations. These Inspect-X reports will be invaluable to Lectronics’ customer base. With a variety of customers in the medical and aerospace industries with Class 3 assembly requirements, Lectronics will now be able to supply these clients with real-time data and 3D visual images that guarantee the solder joints on their assemblies, and thus guarantee the functionality and reliability of the entire PCBA.

“As a future-thinking organization, we are always investing in the appropriate tools and resources to provide our customers with unparalleled quality,” commented Mario Sciberras, Lectronics President and CEO. “This Nikon X-ray will better ensure quality for highly-complex circuit board assemblies with leadless components.”

Sliced 2D images are reconstructed into a detailed 3D model that can be analyzed on any plane with the X.Tract analysis tool.

“ With the Nikon XT V X-ray system, I will definitively know that my manufacturing process is delivering excellent results for all bottom-terminated chip components. Scott Sober – VP of Operations at Saline Lectronics

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