HIGHLIGHTING METROLOGY & MANUFACTURING TECHNOLOGY
ISSUE 02 | JUNE 2025
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The art of CMM performance Hexagon MAESTRO : An exclusive interview SOFTWARE IN Page 16 CONTROL REVIEW
METROLOGY AS A SERVICE Rethinking qualification
MANUFACTURING Measured to perfection
Gauging innovation at Control 2025
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Contents 4 Catch up What’s been happening?
Contact Us
Let’s review : Control 2025 Gauging innovation
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Foundations of metrology Dr. Neil Calder - Measuring between the lines Cover showcase Mastering the art of CMM performance
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Publisher - Laura Crawford laura@measurementandmanufacturing.com Technical Editor - Steed Webzell hello@measurementandmanufacturing.com Contributing Editor - Dr. Neil Calder hello@measurementandmanufacturing.com Advisory - Mark Deadman hello@measurementandmanufacturing.com
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Software in manufacturing Measured to perfection
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Surface inspection Precision at the edge
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Metrology as a service Breaking through the bottleneck Automation The future of efficient manufacturing Roughness & contour Precision and efficiency redefined Precision in electrification Beyond Gigafactories
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We’re excited to have you with us as we delve into the fast-moving world of metrology and its vital role in shaping modern manufacturing. In this issue, you’ll find fresh insights, expert commentary and practical guidance,
© All rights reserved. Measurement & Manufacturing along with it’s contents, should not be copied or transmitted without seeking prior consent from Engineering Media Ltd. You can read our privacy policy by visiting www.measurementndmanufacturing.com The content does not imply our endorsement, where interviews and article contain views, they do not necessarily reflect the views of our editors.
all brought to you by our editorial team with over 60 years of combined engineering experience. From the latest developments unveiled at Control 2025 to proven best practices from across the industry, this edition is designed to inform, inspire and elevate your work. Let’s explore what’s next in measurement and manufacturing, together. Laura Crawford - Publisher
Catch up
Renishaw has renewed its partnership with the Greenpower Education Trust, a UK charity that engages students in designing, building, and racing electric cars to inspire interest in STEM. The renewed three-year agreement includes sponsorship of the Castle Combe Heat which took place in June. Renishaw also supports events for younger students and highlights its commitment to diversity in engineering. With more girls joining Greenpower teams, the initiative continues to spark engineering careers. Many, like Liz Craven, now work at Renishaw. www.renishaw.com Renishaw inspires future engineers
Bowers Group sets new standard in bore gauging accuracy
Bowers Group has enhanced its bore gauging precision by adopting the Baty Venture FV 2020, a fully automated, non-contact vision measurement system. This innovative technology delivers faster, more repeatable results and removes operator variability. “Once it’s programmed, anyone in the factory can run it and get the same result — accurate, every time,” said CNC Grinding Technician Declan Hargreaves. The move reflects Bowers Group’s continued commitment to advancing metrology through innovation and maintaining British manufacturing excellence. www.bowersgroup.co.uk
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Catch up
Large CMMs bring laboratory-grade metrology to the factory floor
LK Metrology has launched eight large-format Altera SF coordinate measuring machines (CMMs), delivering lab-grade accuracy to the factory floor. Designed for in-line inspection of bulky components, the machines offer rapid feedback, reduced scrap, and tighter process control. With temperature compensation, anti-vibration systems, and glass- ceramic scales, they ensure high precision even in uncontrolled environments. Integrated software and automation readiness further boost efficiency. www.lkmetrology.com
The Sempre Group has brought fixture production in-house by investing in its first machine tool, a Hurco VM10i vertical machining centre. The move addresses rising demand for custom automation in quality control. Producing fixtures internally enhances speed, flexibility, and component quality while reducing lead times from weeks to under an hour for simple parts. The machine’s user- friendly controls, tight tolerance capability, and future upgrade potential make it a key asset in Sempre’s Gloucester facility. www.hurco.com/gb Sempre Group brings manufacturing in-house
Control goes biennial The 37th Control international trade fair wrapped up in Stuttgart this May, drawing over 20,000 visitors from 70 countries and featuring 500 exhibitors. The event highlighted major advances in quality assurance and metrology, including AI-driven inspection tools and contactless measurement systems. Organizers announced Control will now be held every two years, with the next edition set for April 2027 reflecting that industry calls for a more sustainable pace to showcase meaningful innovation www.control-messe.de
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Catch up
Aberlink introduces new generation Axiom CMM
Aberlink has unveiled the third generation of its Axiom coordinate measuring machine (CMM), marking the latest development in a series that began in 1995. The original Axiom was noted for making fully error-mapped CMM technology more accessible. The Axiom too followed in 2004, becoming Aberlink’s most widely used model. This latest version integrates updated technology with the company’s long-standing design principles. Enhancements include a redesigned right- hand-side bridge assembly for greater stiffness, a twenty five percent increase in measurement speed, and improved resistance to dirt through upgraded linear encoders. Its updated appearance also aligns it with other recent models in the range. Aberlink continues to manufacture and develop its systems in-house at its Gloucestershire
facility. The new Axiom is
priced over £3,000
less than the outgoing high-spec Axiom too HS model, despite offering similar performance. The machine is supported by Aberlink’s proprietary 3D measurement software, which includes free updates and technical support. The company maintains that this latest Axiom balances value, reliability and performance for modern precision manufacturing needs. www.aberlink.com
igus polymers strengthen microscopes
A mobile microscope from Prechtl TechSolutions has won the 2025 manus plastic bearing competition. A jury of experts recognised the engineers who used lubrication- free polymer bearings and were able to increase the reliability of the microscope. The problem is that users on site are often unable to maintain or repair the devices. If you failed to relubricate the bearing points in the microscope stand, the bearings get damaged and become unusable, wasting resources in a time sensitive environment. However, the company Prechtl Tech Solutions was determined to find a solution. The engineers have developed a lightweight microscope that can be assembled within five minutes without tools and also works
without access to a power supply. In the joints of the microscope, iglidur G polymer plain bearings
from igus ensure maintenance-free and fail-safe dry operation lasting many years, greatly reducing weight compared to metal bearings. This impressed the jury, including representatives from specialist media, industry, research and business, who presented Prechtl Tech Solutions with the gold manus award 2025 and €5,000 prize money. The experts praised its simple and economical design. www.igus.eu/manus-award
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Measurement & Manufacturing
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Let’s review : Control 2025
Gauging innovation at Control 2025 In May, all roads led to the Control 2025 exhibition in Stuttgart, with the Measurement & Manufacturing team among thousands making the pilgrimage to this metrology extravaganza. By Steed Webzell, Technical Editor
The Control exhibition has grown to become the who’s who of metrology, with the 37th edition hosting 500 exhibitors across four halls. In total, over 20,000 visitors from 70 countries flocked through the doors to get a glimpse of the latest and greatest in metrology innovation. Donned in suitably comfortable footwear, the Measurement & Manufacturing team trawled every aisle to unearth never-before-seen ways of making measurement faster, easier and smarter. The stand of Hexagon was exceptionally
crowded, with hordes of visitors surrounding the exhibits. Key among them was the new Leica ATS8000 laser tracker, which cuts the inspection time of large items such as aircraft structures, ship hulls and wind turbines from hours to just minutes. High-accuracy reflector-less scanning at distances of up to 40m powered by patented TruePoint technology means no scaffolding or target placement is necessary. Also attracting much attention was Hexagon’s PRESTO quality station, a turnkey
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Let’s review : Control 2025
measurement cell which, at Control 2025, was measuring the front end of an Oracle Red Bull Racing Formula 1 car. Shown featuring Hexagon’s new HYPERSCAN optical tracker with 3D scanning device, even non-metrologist shop-floor operators can improve efficiency with high- speed, high-resolution part scanning, supported by simple set-up and easy programming. Another star product introduction was the Hexagon Maestro next-generation CMM. Fast, easy to use, fully digital and scalable, the machine was busy measuring an alloy wheel. According to the company, its new Maestro is the fastest CMM in the world, surpassing the previous fastest machine, Hexagon’s Global S. Jörg Deller, General Manager - Stationary Metrology Devices and MTM, revealed that a speed comparison involving the Maestro and Global S measuring an identical motorsport component, showed the former to be significantly faster. The Global S completed the measurement routine in 140 seconds, while the Maestro took only 90 seconds: 35% quicker. Points of distinction Among other new CMMs catching the eye at Control 2025 was the CRYSTA-Apex VPlus 574 from Mitutoyo. Measuring a complex aerospace part at the show, the machine is ready for use in a smart factory environment with its temperature sensors for machine and workpiece compensation
offering an extended range of 15-30°C. Using Mitutoyo’s ABS scales, the CRYSTA-Apex VPlus 574 has a high resistance to environmental conditions and does not require homing upon start-up. Billed as a future-proof investment, Mitutoyo says the high-accuracy, high-speed, high-acceleration CMM is capable of tackling almost any task thanks to its ability to change or add probe systems and software with ease. LK Metrology was also promoting a new CMM suitable for shop-floor use in the shape of its new Altera SF (Shop Floor). The Altera SF withstands temperature shifts, vibration and dust without compromising its lab-grade accuracy, reports LK. On the stand, Sales & Marketing Co-ordinator Adam Tomlinson pointed out the presence of 360° status lights on top of the machine, while operator safety devices such as light curtains are optionally available.
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Let’s review : Control 2025
in the measurement of part features; hyper-fine scanning for capturing details of complex objects with maximum resolution; photogrammetry to maintain best accuracy over large objects; deep- hole scanning for hard-to-reach areas and holes; and large-area scanning for capturing sizeable features. On the opposite side of the aisle sat Keyence, which was keen to showcase the virtues of the company’s new VL-800 series 3D Scanner CMM, the first in its line-up to feature 3D-AI for the effortless acquisition and analysis of high-quality 3D data. According to Konstantin Otto, Area Product Sales Manager, the system intelligently recommends optimal scanning, stitching and measurement methods based on the shape of the part under scrutiny. The stand of Micro-Epsilon showcased the company’s new 3D Profile Unit, which
Another stand-out CMM at Control 2025 was Wenzel’s new LH1210. Measuring a crankshaft at the exhibition, Wenzel developed this hybrid machine to offer greater measuring accuracy and speed. The LH1210 can support tactile measuring systems such as the Renishaw REVO five-axis measurement system and optical sensor solutions like the Wenzel LS 150, as well as the company’s CT solution for non-destructive metrological testing. A good example of the portable CMM technology on show was the new PMT GAMMA, which is available in the UK from Manchester Metrology. Designed for high-precision, flexible and real-time inspection/measurement, PMT Gamma 3D measuring arms are built with lightweight aerospace-grade carbon fibre and offer enhanced stability and usability with their dual-suspension support structure. The range includes three models catering to various budgets and applications. Leap forward With FARO’s new Leap ST 3D handheld scanner, the company is very much focusing on application versatility. Peter Bambridge, Senior Account Manager at Faro UK, was on hand to demonstrate this new compact, high-accuracy scanner with no less than five operating modes: ultra-fast scanning for speedy coverage
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Let’s review : Control 2025
enables smart 3D evaluation and output of stitched 2D/3D laser line profile data. In effect, the 3D Profile Unit aids the measurement of complex geometries by organising several laser scanners into a common co-ordinate system. This capability makes it possible to measure and inspect entire outer contours, undercuts and thickness volumes. Another neat innovation could be seen on the stand of Marposs. According to the company, SMARTNet is more than just a fast network; it’s a smart, plug-and-play architecture created to simplify connections, minimise set-up and reduce costs. On the stand, Global Marketing Manager Mariangela Bettini said SMARTNet’s fully digital backbone makes measurement networks easier to configure, faster to maintain and more intelligent. X marks the spot According to Andreas Graf, Project & Sales Engineer at Werth Messtechnik, users of the company’s new and ultra-compact Tomoscope XS Plus 230 can solve even more measurement tasks faster, more accurately and therefore more economically using X-ray CT (computed tomography). Werth says its long-life transmission sources offer five times faster measuring speed and better economy than systems with conventional X-ray sources. Said to be the most powerful transmission source on
the market with up to 140W, the Tomoscope XS Plus 230 is suitable for applications such as the measurement of prismatic battery cells used in the automotive or e-bike industries. A further new offer in this technology area was present on the stand of Zeiss. The Metrotom 800 320kV is designed for the high-precision inspection of dense materials like Inconel, cobalt chromium and additively manufactured metal parts or multi-material assemblies. Robert Zarnetta, Head of Customer Segment Management, suggested that the Zeiss Metrotom 800 - now with 320kV in the X-ray range - is ideal for the quality assurance of turbine blades. Eyeing the future Taking the spotlight on the stand of Vision Engineering was its new EVO Cam HALO digital microscope. Carrying the strapline ‘4K inspection made easy’, the company says EVO Cam HALO digital provides ultra-HD image quality, supported by precision and versatility. The microscope features intelligent features, such as automatic lens identification and a super-wide dynamic range for brightness and contrast. The booth also featured a ‘portal into the future’, with Group Sales & Marketing Director Paul Newbatt present to explain a number of forthcoming innovations in digital 3D visualisation. These included a system that performs eye pupil tracking to create Measurement & Manufacturing 11
Control 2025 Review
True to form Making its global launch on the Bowers stand was the new Figura range of contour, form and roundness measurement machines. Expertly explained by Product Development Manager Emma Bramley, feature-rich Figura machines are fast, easy-to-use and offer single-figure micron accuracy. The Figura RD is capable of high-accuracy measurements that include roundness, cylindricity, straightness, concentricity, flatness, full run-out, parallelism and perpendicularity, while the Figura CR is for contour, surface finish and roughness. According to Bowers, market differentiation arrives courtesy of the capabilities provided by the integrated measurement analysis software. As many would expect at a metrology exhibition, there was a plethora of industry- familiar measuring instruments on display. Stand-out exhibitors here included Insize UK with its wide range of quality bore gages, hardness testers and hand tools. Catching the eye was a new vision measuring system, launched at the show, which will be available in the UK market in 2026/2027. Exhausted but enlightened with new knowledge and a vision of the future, the Measurement & Manufacturing team headed home to begin looking forward to the 38th edition of Control, set to take place on 27-30 April 2027. n
an advanced 3D stereo image on a flat screen, while another innovation highlighted the splitting of a mono image into a stereo image, providing an extra dimension without requiring the operator to perform any guesswork. The theme on the stand of Mahr was ‘discovering optical metrology’, as highlighted by the innovations on display. In particular, with the acquisition of Optosurf, Mahr has expanded its portfolio to include scattered light technology. Several such devices were presented for the first time in Stuttgart as part of the MarSurf3D family. For example, it is possible to integrate the MarSurf3D Sensor OS 500 scattered light sensor into the control systems of machines like grinders or linishers to measure roughness and waviness exactly where it matters: directly inline. Accretech used Control 2025 to highlight its Opt-Scope NEX non-contact surface roughness/ texture and contour measuring machine, which was making its debut appearance in Europe. Suitable for high-end applications, including medical parts, the Opt-Scope NEX can measure fine surface roughness and geometry at nano- and sub-nanometre-level. Key here, explained the company’s Regional Director for North Europe Tim Wood, is the use of white- light interferometry that takes advantage of Accretech’s proprietary DEAP envelope/absolute phase detection algorithm.
12 Measurement & Manufacturing
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In the first issue of this magazine I wrote about metrology in connected digital manufacturing, and the value of being informed in real time, presenting very much a future view. I would like to develop that by digging into the foundations of measurement for manufacturing and looking back at where this current capability has come from. with Dr. Neil Calder Measuring between the lines Foundations of metrology
It is always important not to forget our engineering heritage, and to recognise the shoulders of which giants we stand on. Early science lessons in school are centred around measuring things and are the first real confluence of numbers with the world around us. I recall measuring the dimensions of our primary school playground with a rudimentary metre stick and being disappointed (or even affronted) at the relative inaccuracy of this. Later, as a practicing researcher in manufacturing engineering it was more normal to have a Vernier calliper or a micrometer within arms reach and I have become comfortable with that. These are still tools which are found in the workbench drawers of even the most advanced shop floor that I visit, despite the former dating from around the 1820s and having existed almost unchanged in its analogue form for the last two hundred years. The neat trick that Pierre Vernier developed a couple of centuries before that to increase measurement accuracy of graduated scales by an order of
magnitude by concentrating on minute but discernible differences is paralleled to some degree in the optical interferometry techniques which powers accurate laser measurement today. I had the occasion to attend an evening business function at the Musee des Artes et Metier in Paris a few years ago which included an after-hours tour through the museum’s artefacts.
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Foundations of metrology
In 1841 Whitworth was the first to establish a national thread standard which bears his name. Prior to this there were local standards within companies or pockets of industrial sectors but little which would lead to widespread interchangeability. His experience with threads led to the development of the highly accurate hexagonally rifled musket which is reputed to have allowed a Confederate sharpshooter to kill union General John Sedgwick from a range of over 1000 yards, just after he had famously proclaimed “they couldn’t hit an elephant at this distance”. Both Vernier and Whitworth were able to squeeze more accuracy out of contemporary measurement systems than their peers. I can’t help wondering what use they could make of modern measurement tools. n “I recall measuring the dimensions of our primary school playground with a rudimentary metre stick and being disappointed (or even affronted) at the relative inaccuracy of this.”
What impressed me then, more than the canapes and champagne, was the priority in 17th and 18th century France which was afforded to measurement machines and standards (there was a lot of brass and cast iron involved!) and which explains the impetus which Vernier had. This wasn’t just for scientific curiosities, but was baked into the very social fabric of the nation. There remains to this day two of an original 16 public marble metre standards from the time of the French revolution, embedded in the walls of a couple of otherwise innocuous buildings in the centre of Paris. Joseph Whitworth was the darling of later Victorian industrialisation on the manufacturing shop floor although with more direct impact on the toolroom than in the factory sweatshops and dark satanic mills of the period. He can be justifiably anointed the father of the “thou” by enabling a practical methodology of measurement for going beyond the traditional halving fractions of 1/32, 1/64, etc. of an inch
and later in the century managed to create a machine capable of measuring to a
millionth of an inch within a single linear dimension. This was basically a micrometer the size of a lathe.
Measurement & Manufacturing 15
Cover showcase
Mastering the art of CMM performance Steed Webzell, Technical Editor of Measurement & Manufacturing speaks exclusively with Manuel Müller, Senior Product Marketing Manager at Hexagon, about the company’s new CMM market disruptor: MAESTRO
In a continuously evolving economic landscape, manufacturers must stay laser-focused on efficiency, throughput and cost reduction. And while challenges remain, the digital revolution delivers a golden opportunity to reshape industry conventions through the convergence of technology, hyper-connectivity and data analytics. It seems the perfect time to reimagine a manufacturing mainstay: the coordinate measuring machine. Manuel Müller, Senior Product Marketing Manager for Stationary Machine Tool
Measurement at Hexagon’s Manufacturing Intelligence division, says: “Here at Hexagon we’ve been developing CMMs for decades, with each iteration a little better than the last. But this time we took a different approach. We thought about what we’d conceptualise if CMMs didn’t exist and this was our chance to design a coordinate measuring solution from the ground up with little consideration for the limitations of existing technology. The result of that process was MAESTRO, a CMM that overcomes what our customers state are their four biggest
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Cover showcase
pain points: throughput, skill gaps, connectivity and future-proofing/ scalability.” The need for speed It’s well documented that CMMs can sometimes prove the bottleneck in manufacturing processes. “With MAESTRO, we sought to change all that, developing a machine
intuitive software and hardware ecosystem. For instance,
Metrology Mentor software automates programming to
deliver rapid, reliable and repeatable collision-free CMM programs in a few clicks without any need for coding. Users can also take advantage of Metrology Reporting software to share real- time information and insights, while
that not only offers ultra-fast measuring speed, but accelerates the whole metrology workflow to keep pace with production,” states Manuel. Hexagon says the new CMM offers the highest speed in its class, with traverse up to 6,500mm/s and measurement up to 1,100mm/s. However, this machine is about far more than axis speeds. It has the ability to move all five axes simultaneously during positional movement, while a 360° B axis allows infinite rotation and software selects the shortest rotational movement to the next sensor position. Despite the higher speeds, the machine offers the same accuracy as Hexagon’s existing portfolio of best-selling GLOBAL bridge-type CMMs. Notably, users can alter the speed/ accuracy ratio at the push of a button, sacrificing speed in favour of more accuracy and vice versa. Bridging the gap Historically, CMMs have proved notoriously difficult to use with only skilled operatives able to achieve the best levels of performance. “With the skills market currently failing to meet demand, there’s a need for CMM technology that’s suitable for use by everyone, from seasoned quality professionals to non- metrologists,” explains Manuel. MAESTRO users can simplify every part of the measurement workflow using the
Metrology Asset Manager tracks equipment use and identifies bottlenecks and spare capacity. “Crucially, the all-digital, self-aware MAESTRO CMM system offers instant synchronisation to a digital twin, for reduced risk of collisions and faster set-up times,” he explains. “Digital machine
components [such as sensors and racks] are instantly identified and initialised when mounted and synchronised with the digital twin. In addition, integration with industrial
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Cover showcase
Bright future Customers told Hexagon they wanted a CMM with a high degree of future-proofing and scalability. “With this in mind, we made sure MAESTRO can evolve via easy upgrades in the field, even years after initial set-up,” says Manuel. “We’ll design any sensors we release in the coming years to perform on existing and future MAESTRO machines.” As a point of note, the recent Hexagon Live Global 2025 event in Las Vegas, saw the company launch its Autonomous Metrology Suite. The suite enables, among other machines, Hexagon’s existing GLOBAL S, TIGO SF and new MAESTRO CMMs to join the same digital workflow, meaning existing investments continue to pay dividends. Potential applications for MAESTRO are wide ranging. They include GD&T-compliant parts such as gearbox housings, precision components with freeform surface components (like turbine blades), and moulds and moulded parts with functional geometries. With its planning, programming, set-up/ execution and analysis/reporting attributes, MAESTRO clearly has the potential to become an integral component of the smart manufacturing era. n hexagon.com/products/maestro
automation has never been simpler.”
The machine also connects to Hexagon’s entire cloud-based Nexus ecosystem for the delivery of measurement data to smart manufacturing environments. Making connections Hexagon’s all-digital, connected CMM system facilitates data-driven decisions that boost productivity and quality. It features newly- developed digital architecture, incorporating digital sensors, a single cable system, and a completely new controller and firmware. “MAESTRO is an industrial IoT device by design, so it provides data that includes important controller and wrist information, machine status, remaining measurement time, sensor configuration, calibration data, and more. The digital system also enables remote access in service and support cases. This takes advantage of a live feed to the machine through a built-in camera.”
18 Measurement & Manufacturing
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Software
Measured to perfection Reitz Natursteintechnik KG, specialises in the production of
Why Granite? Natural hard stone may seem an unlikely choice in high-tech engineering, but it offers unique advantages over traditional materials such as steel or mineral casting. “Granite has remarkable qualities – thermal stability, vibration damping, dimensional accuracy – that make it ideal for machine beds, test stands and measuring systems,” explains Reitz. Reitz typically supplies surface plates, structural frames and tables. Granite is sourced from quarries in South Africa, Spain, France and Austria. It arrives as raw blocks or slabs and is machined in-house. Sizes vary from 250 x 250 mm to 13 metres in length, with the largest piece weighing 65 tonnes. The company operates four gantry-type milling machines and two 5-axis gantry systems, all fitted with Siemens 840D controls. Simulation ensures safety Granite’s natural surface irregularities and hardness (Mohs 6–8) make it challenging to machine. To address this, Reitz uses VERICUT
Founded by Herrmann Reitz, the company started with stone quarrying. Today, under the leadership of Christopher Reitz, it focuses on advanced granite processing for precision applications. “Today’s components combine million- year-old stone with cutting-edge technology,” says Reitz. “For more than 35 years, we’ve been producing precision granite parts – offering everything from system assembly to bespoke solutions, all from a single source.” highly precise machine components made from natural granite. With a heritage dating back to 1946, the company expertly combines age-old material with modern machining technology. To ensure quality and process reliability, it relies on the VERICUT simulation system.
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Software
software to simulate every process step in advance. “Granite surfaces are never perfectly flat,” says Reitz. “Using VERICUT, we simulate the operation and eliminate the risk of tool collisions or machine damage.” “Manual setup is no longer required,” adds René Maschlanka, who oversees sales and project management. “It saves time, protects the machine and increases operator confidence.” Precision workflow Granite blocks typically have a 3 to 5 mm material excess. Final machining tolerances are as tight as 5 to 20 microns, but only 0.1 mm can be removed per pass due to the stone’s hardness.
Digital twin in action Reitz uses a dedicated CAM system adapted for granite, with a custom interface to VERICUT. “We created an interface that reflects the exact workpiece geometry and position,” says Maschlanka. “This lets us simulate every operation step without manual input.” This helps detect clamping errors, unnecessary tool movements or incorrect tool use before production begins. With some jobs running over 40 hours, operators no longer need to monitor machines continuously. “The VERICUT Reviewer helps determine when checks are required,” adds Reitz. Supporting the team The VERICUT Reviewer allows simulations to be viewed on any Windows PC or tablet. “Operators and engineers can confirm the programme visually, which boosts trust and improves planning,” says Meurisse. “Our team really values the Reviewer. It highlights critical process points and supports setup tasks like tool and clamp selection,” adds Maschlanka. With VERICUT in place, Reitz Natursteintechnik has significantly reduced errors and increased machining confidence. “VERICUT is easy to use, prevents mistakes and gives our team peace of mind,” concludes Reitz. Meurisse adds: “This was an exciting challenge. We normally simulate metal – not granite. VERICUT proved it can safely handle even multi-tonne natural stone components.” n www.vericut.com/uk Measurement & Manufacturing 21
“After inspection, the operator selects a probing pattern,” explains Maschlanka. “This generates two CAM programmes: one to locate the block and one to map the surface using probing cycles.” Probing takes up machine time, so it’s used efficiently. The data is converted into NC code and run through VERICUT to verify safety before machining begins. “The surface map shows the true shape of the workpiece. From this, a machining strategy is created and simulated before cutting starts,” says Stephan Meurisse. After roughing, the cuboid is drilled for rails, sensors or spindles. Threaded inserts are glued into place, and finishing is completed in a climate- controlled lab.
Surface inspection
Precision at the edge
Advanced metrology meets practical engineering as Fintek enhances edge preparation accuracy for high-performance cutting tools.
In the realm of high-precision manufacturing, where margins for error are virtually non- existent, the fine details make all the difference. For Fintek, a surface finishing specialist based in Lancashire, the quality of cutting tool edges is one such detail that plays a vital role in tool performance and product finish. Serving a wide range of sectors including aerospace, motorsport, automotive, medical devices, and precision engineering, Fintek has built a reputation for delivering world-class subcontract surface finishing services. Now, the company is strengthening that position by integrating the Bruker Alicona EdgeMaster into its measurement and inspection capabilities.
Supplied by Optimax Imaging and Inspection, this advanced system allows Fintek to carry out highly accurate and repeatable assessments of edge rounding and burr classification, two critical aspects of tool preparation. Edge preparation is far more than a finishing touch. It directly affects tool wear, chip formation, and the surface quality of machined components. As Fintek explains, accurately preparing and verifying these micro features is essential to ensuring that cutting tools deliver consistent and reliable performance. Without precise measurement, even the best surface finishing processes risk falling short of their potential. The Alicona EdgeMaster provides a solution
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to this challenge by offering detailed insights into the micro geometry of cutting tools. While the system will initially be used for measuring edge prep, its capabilities extend far beyond. It can also assess shape and contour accuracy, rake angle, undercuts, chipping, and the roughness of the chip face. This comprehensive approach ensures that the most critical parts of the cutting tool are fully understood and controlled. One of the major advantages of the system is its usability. Traditionally, such high-precision metrology tools have required specialised training and operation by experienced technicians. The EdgeMaster, however, has been successfully introduced to the shop floor at Fintek, where personnel with no previous metrology background have been trained to use it effectively. This accessibility means that precise measurement and quality assurance are now seamlessly integrated into the production environment. In addition to real-time measurements, all data is stored and managed through Alicona’s powerful software. This includes a built-in database that allows for easy retrieval and full traceability, supporting robust documentation and compliance with customer specifications. By developing exact edge treatment requirements with customers and verifying them during production, Fintek ensures that every tool meets strict performance standards. This investment in advanced metrology is more than a technological upgrade. It reflects Fintek’s broader mission to deliver precision, reliability, and innovation across every stage of the surface finishing process. By equipping its team with the tools to measure and manage even the smallest of details, Fintek is ensuring that its customers receive not only high-quality tools, but also a measurable advantage in
performance and productivity. n www.optimaxonline.com
Metrology as a service
Breaking through the bottleneck How AddQual is using metrology to rethink manufacturing qualification
In the world of high-stakes manufacturing, think aerospace, power generation, and medical devices, there’s little room for error. Every component has to be perfect, every measurement exact. Yet the process of verifying and qualifying these parts can be... well, a bit of a nightmare. Scrap costs pile up. Production slows to a crawl. Launches get delayed. Sound familiar? It’s a pain point that Ben Anderson knows all too well. “Personal pains,” he calls them. As the founder and Managing Director of AddQual Ltd, Anderson set out to tackle the inefficiencies of traditional qualification head-on by putting metrology, the science of measurement, at the very heart of manufacturing quality. “I saw it again and again,” he recalls. “Manufacturers were generating mountains of measurement data, but there was a massive gap between having the data and being able to make confident decisions from it. Everything felt slow, expensive and, frankly, prone to human error.”
focus: helping manufacturers of safety-critical components qualify parts quickly, consistently and with full confidence. Their suite of services is designed to cut through the chaos that plagues traditional quality assurance. From supporting component qualification to optimising production inspection and guiding Continuous Improvement (CI) investigations, AddQual is reshaping how businesses think about quality. One of the company’s core offerings is its component qualification service, handling metrology data capture and reporting for everything from tiny 2mm³ parts to whopping 2m³ structures, across all manner of materials. “OEMs and MROs often come to us with incomplete or unclear inspection requirements,”
Changing the game, one measurement at a time
AddQual isn’t just another quality control firm. It’s a metrology-driven mission with a clear
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Anderson explains. “It leads to delays, confusion, and costly rework. We work alongside them to fine-tune and clarify those requirements, making sure they’re not just ticking boxes but actually aligning with industry standards.” In practice, that means creating dimensional metrology systems that are integrated into the customer’s workflow. It’s metrology done with purpose and precision. From data deluge to clarity Production inspection is another space where AddQual makes a big difference. Today’s manufacturers are swamped with data, but not all of it is useful. In fact, too much of it can be paralysing. “Companies are drowning in spreadsheets and reports, yet starved of insight,” says Anderson. “We help them break out of that doom loop by combining metrology expertise with clever fixturing, automation and data management software.” The result? Processes that are less reliant on gut instinct and more informed by structured, traceable data. Engineers can stop second-guessing and start improving, with speed and certainty. Investigating the issues, properly And then there’s the dreaded ‘what went wrong?’ moment. When inconsistencies crop up or components fail, manufacturers need reliable answers fast. “Paper-based systems and manual decision- making just don’t cut it anymore,” Anderson says. “Too many critical decisions still hinge on subjective judgement. That’s risky.” AddQual’s CI Investigation services are built around structured metrology data, collected using advanced 3D structured light techniques, CMMs, callipers, micrometres and other inspection tools. Combined with NADCAP- accredited processes, this data is trustworthy
enough to support real root cause analysis and lasting improvement. Breaking down the silos Another big headache in manufacturing is data fragmentation. Different systems store different data in different formats. It slows everything down, introduces human error and makes integration a nightmare. AddQual tackles that problem head-on. Their platform transforms raw measurement data into structured, traceable insights. That means faster decision-making and less time spent trying to make sense of conflicting reports. “Our whole aim,” Anderson sums up, “is to automate quality control decision-making. We want to remove variability, improve responsiveness, and let manufacturers focus on making great products, not just measuring them.” Metrology, with a mission By placing structured metrology and autonomous inspection at the centre of its
strategy, AddQual has carved out a unique role in the manufacturing world. It’s not just about better measurements. It’s about better outcomes. For businesses facing the pressure of compliance, consistency and cost, AddQual
offers more than just a service. It offers peace of mind. Because in an
industry where there’s no room for guesswork,
precision isn’t a luxury. It’s a necessity. n www.addqual.com
Automation
The future of efficient manufacturing Exploring industry transformation with The Sempre Group In today’s fast-paced industrial environment, manufacturers are under increasing pressure to streamline operations, cut costs, and uphold stringent quality standards. To address these demands, many are investing in automation and smart fixture technologies.
Automation has long played a pivotal role in modern manufacturing, but recent advances in intelligent systems have propelled efficiency to unprecedented levels. These next-generation technologies go beyond repetitive task execution. Leveraging artificial intelligence (AI) and machine learning (ML), they can now adapt to real-time changes, enabling manufacturers to minimise human intervention, reduce errors, and maintain consistently high-quality outputs. Robotic arms on assembly lines and fully automated inspection stations are now common in advanced manufacturing environments. These systems not only speed up production but also ensure uniformity and safety by performing tasks with unwavering accuracy. As a result, manufacturers can meet industry standards with greater confidence and consistency. Enhancing precision with smart fixtures While automation addresses many production challenges, smart fixtures offer a critical layer of support. These innovative tools are designed to hold, support, and precisely position components during manufacturing and inspection processes. Unlike their traditional counterparts, smart
fixtures are embedded with sensors and software that deliver real-time data and feedback. This intelligent integration enables manufacturers to significantly reduce setup and changeover times, detect anomalies during production, and eliminate the variability associated with human operators. By ensuring that each component is consistently aligned and inspected under the same parameters, smart fixtures enhance both repeatability and reliability—key factors in industries where precision is paramount. One of the most transformative aspects of modern manufacturing is the integration of real-
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time data acquisition. Automation systems and smart fixtures contribute to a continuous data stream that enables proactive decision-making. Engineers and operators can identify bottlenecks, predict equipment failures before they occur, and optimise processes based on comprehensive, real-time insights. According to Jim Mangan, Managing Director at The Sempre Group, “The combination of automation and smart metrology solutions allows manufacturers to increase throughput while maintaining the highest standards of quality. By implementing intelligent fixtures, companies can eliminate operator variability and improve measurement reliability.” Sectors such as aerospace, automotive, medical device manufacturing, and precision engineering are leading adopters of automation and smart fixtures. These industries require ultra- reliable, high-performance solutions that meet rigorous regulatory standards. By embracing
smart manufacturing practices, companies in these fields are not only improving output and precision but also supporting more sustainable operations by reducing waste and rework. A strategic shift in manufacturing Automation and smart fixtures are more than just emerging technologies, they represent a strategic evolution in how products are designed, built, and validated. Forward-thinking manufacturers that adopt these innovations gain a competitive advantage by increasing flexibility, shortening production cycles, and consistently delivering high-quality products. The Sempre Group continues to support manufacturers across diverse sectors by offering tailored automation and metrology solutions. Their expertise helps businesses optimise operations, reduce inefficiencies, and uphold quality throughout every stage of production. n www.thesempregroup.com
Precision in electrification
Beyond Gigafactories Why custom battery pack manufacturing is critical for OEMs
We hear from Alex Stapleton, CCO, Alexander Battery Technologies.
Gigafactories dominate the battery sector, attracting the bulk of investment, media attention and policymaking. Their impact on the automotive industry is undeniable. But for many OEMs outside that space such as those in medtech, robotics and niche EVs, they aren’t the answer. These sectors need flexibility, speed and engineering support that large-scale cell plants aren’t built to deliver. At first glance, this may seem like a volume issue. But the real challenge is adaptability. Gigafactories are built for scale: fixed formats,
long-term programmes and processes that reward consistency. That works for automakers producing millions of vehicles. For OEMs building in the tens of thousands or just a few hundred it can be a poor fit. They need partners who can move quickly, accommodate change and support technically complex products through design, testing and certification. Such OEMs often work in fast-changing environments. Requirements shift, regulations emerge, and product specs evolve. Rigid production schedules or inflexible designs can
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