NIKON METROLOGY NEWSVOLUME 13

X-ray imaging facility develops world leading research

iNEXIV video measuring system accelerates PCB inspection

Laser scanner is irreplaceable for analysis of 3D-printed implants

MICRO-CT ENABLES TOTAL PROCESS CONTROL FOR ADDITIVE MANUFACTURING

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Industry 4.0 aims to increase competitiveness by a more efficient production process with quality instilled from beginning to end. It fundamentally changes the role of the quality department: the goal is no longer to control quality but rather to drive the production process to consistently deliver products with the right quality. This is called “Quality 4.0” that builds on the latest developments in device connectivity, cloud computing and artificial intelligence. The effectiveness of “Quality 4.0” however highly depends on the data that drives it. Future-proof inspection systems are characterized by :

• Digital inspection - enabling direct comparison with CAD data

• Automated inspection - providing operator-independent, reliable data, in a timely fashion

• Connected inspection - ensuring better part traceability and feedback to up- and downstream production steps

Nikon Metrology provides a full portfolio of automated Computed Tomography, non-contact 3D metrology and video measurement solutions that can be deeply integrated in the manufacturing process.

Using Nikon’s Laser Radar technology, automotive OEMs can now do CMM-quality body-in-white inspection directly on the shop floor, much faster than before. It enables them to shorten pre-series cycles and improve process control.

Quality 4.0 is not anymore about looking backwards, but about predicting and controlling quality for today’s and future production.

DRIVING QUALITY 4.0DIGITAL I AUTOMATED I CONNECTED

NIKON METROLOGY I VISION BEYOND PRECISION

3News I Volume 13

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4 | Imaging facility develops world leading research

7 | Automotive supplier identifies mystery error using Nikon laser scanner

11 | Sintavia gets the inside track with micro-CT

14 | Improving quality of treatment for patients - The LC15Dx laser scanner is irreplaceable for analysis of 3D-printed implant screw holes and surfaces

17 | Nikon Metrology & Roush Yates engines announce tech partnership

18 | iNEXIV video measuring system accelerates PCB inspection

21 | Insight into the Inside X-ray inspection of solder quality – Nikon Metrology XT V 160 checks power semiconductor devices in production line

24 | Laser scanning cuts cycle times by 50%

26 | Scottish company improves the way it interprets Nikon Metrology's CT scans of rock core samples

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Check out Nikon Metrology on LinkedIn to find out more about our new products, events and promotions

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In the Henry Moseley X-ray Imaging Facility at The University of Manchester, the unique versatility of the Nikon CT systems enable its staff members to take on a great range of research and commercial projects. Nikon CT systems have been installed in the facility for almost 20 years, and they remain the workhorses of the facility today.

Imaging facility develops world leading research

The University of Manchester has been using Nikon CT for almost 20 years. The first system – an XT H 225 - was installed in the year 2000. Following this first investment, the Henry Moseley Facility was established in 2003, based around the capabilities and the flexibility of the XT H 225 and the newly built Nikon 320 kV large-envelope system. Subsequent installations followed, and today, there are 11 imaging systems in the X-ray Imaging Facility, three of which are Nikon systems.

The three Nikon systems include the original XT H 225 cabinet system, a custom built large-envelope system with exchangeable 225/320 kV micro-focus sources, and the XT H 320 large-envelope system complete with 16bit detector. The Nikon CT systems are the workhorses of the facility and take on the majority of inspection projects. Both large-envelope systems have the capacity to hold specimens up to 100 kg and can comfortably scan large samples, but the high-flux X-ray targets enable high-speed scanning. These large-envelope systems have the capacity for sizable in-situ

rigs which help to conduct time lapse studies. The original XT H 225 is on the other end of the spectrum, specialising in scanning much smaller samples but still giving quick results.

The versatility and the reliability of these systems has seen them take on a wide range of projects from the first installation to the present day. The Nikon systems offer unique customisation and the interchangeable sources make them adaptable to various sizes and densities of samples.

Fast and easy to use with a wide range of energiesThe facility is open to external companies, for sub-contract inspection in industrial applications as well as the standard research projects. There are a lot of high-end investigations that take place, however there are also often new users. The facility was initially opened for research, but from the start it was obvious with such a novel capability that there

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The Henry Moseley X-ray Imaging Facility at University of Manchester helps develop world leading research

Case study

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was an opportunity to help a range people complete various projects.

Tim Burnett, Deputy Director of the Henry Moseley X-ray Imaging Facility explains that the ease-of-use of the Nikon Metrology CT systems is why they are perfect for first time users. That, combined with the versatility of the systems makes them the go-to machines.

“The XT H (225) and the large-envelope systems are perfect for exploratory work because they are quick. With a large range of energies they are able to look at a lot of different materials and samples”, Tim Burnett, Deputy Director of the Henry Moseley Facility.

Industrial and commercial projectsWith such a broad spectrum of capabilities in the facility at the University of Manchester, and a wealth of expertise available, the laboratory serves to support industrial projects. One member of staff at the Henry Moseley facility is currently working full-time with the industrial customers who come to the facility. Although run as a service, the projects are still largely research based, with investigative analysis being the main field of work.

More mainstream inspection projects include analysing composites and failures in metals and looking at defects in additive manufactured components.

A lot of people are now starting to understand what is possible, and people want to come and work with the staff at the Henry Moseley Facility to discover more for themselves.

This has led to a number of cultural projects, with the Facility working closely with museums to scan a range of artefacts. For example, the CT systems have helped reveal the contents of ancient mummies and helped check the authenticity of the Jules Rimet football world cup trophy.

Working towards the optimisation of micro-structures in additive manufacturingThere has recently been an increase in additive manufacturing research projects, in collaboration with the University of Sheffield. For these research projects there are two main themes:

1. To look at how well the shape of the final component resembles that of the design, looking at the tolerance of design and any distortions which take place in manufacturing.

2. Looking for internal defects and voids which are often part of the manufactured product. Some of these are large inter-particle voids due to incomplete sintering and others, much smaller voids are that could have been present in the original powder.

These additive manufacturing research projects are all part of working towards the optimisation of micro-structures. A large part of that is getting rid of the defects. With Nikon Metrology CT, non-destructive inspection of additive manufactured components is taken to the next level, providing the inside insight. It is the optimal solution for assuring internal and external geometry by revealing defects, porosity, contamination or cracking. By using Nikon CT, manufacturers have much more confidence in the final component, and researchers can work towards the optimisation of these micro-structures.

Nikon CT enables implementation of 4D CT by IPCThe three Nikon systems offer a unique flexibility, and complement each other in their capabilities. The scale and speed of the systems means the facility is able to take on plenty of new challenges as well as the researchers own projects. These research projects include exploiting the IPC (inter-process communication) interfaces, which will be looked at closer in an upcoming story with Parmesh Gajjar, Research Associate at the Henry Moseley X-ray Imaging Facility. IPC opens up a whole new range of possibilities and ways in which users can get the most out of a system.

At the University of Manchester, IPC has been used to help implement 4D CT – the

“ The XT H (225) and the walk-in rooms are perfect for exploratory work because they are quick, and with a large range of energies they are able to look at a lot of different materials and samples.” Tim Burnett, Director of the Henry Moseley Facility

Parmesh Gajjar, Reasearch Associate at the Henry Moseley X-ray Imaging Facility operating on the XT H 225 WIR (walk-in room).

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introduction of time to inspection projects. For example, the Nikon system can be scheduled to scan biological specimens intermittently. Scans are taken over a set amount of time at intervals, and the growth of the specimen can be illustrated in a video made from the individual time-lapse CT scans, a 3D version of time-lapse photography.

The workhorses of the facility“The XT H 225 and the custom bay, and increasingly so the high-flux bay, are very much the workhorses of the facility. They are very heavily used by internal and external academics, as well as commercially”, Tim Burnett says.

With commercial work accounting for approximately 20% of the activities at the Imaging Facility, the custom bay serves as one of the main tools. Tim explains that there is a huge range of components which can be scanned using this system, from meter size objects down to millimetre sized objects. Not only have the systems been there for a long time, they are used pretty much 24/7, and commercial work is a large chunk of that. The range of component scale, the energy range and speed means the Nikon systems are capable of completing tasks that other systems can’t handle.

Another benefit of the Nikon systems’ versatility is that more often than not, they are able to say yes to commercial requests, which otherwise would have to be turned

down. So long as the component is within the size and density range, people needing a quick answer have often been satisfied. Components can be scanned in less than an hour and reconstructed to take a closer look at. Tim adds that only Nikon systems are capable are carrying out such tasks as quickly; they are perfect for taking a first look in these circumstances.

With these Nikon systems, The X-ray Imaging Facility is able to take on more industrial work, and carry out inspection tasks much quicker and successfully than would be possible with other machines. The range of component scale, and the range of energy sources make it possible for various objects to be scanned, and reconstructed very quickly. In summary, the Nikon CT systems are an invaluable part of the Henry Moseley X-ray Imaging Facility, with the unique customisable ability providing staff and academic researchers with endless possibilities.

“ The XT H 225 and the custom bay, and increasingly so the high-flux bay, are very much the workhorses of the facility. They are very heavily used by internal and external academics, as well as commercially.”Tim Burnett, Deputy Director of the Henry Moseley Facility

Observing the results of the mechanism which shakes the beads at intervals between CT scans.

Loading a mechanism inside the CT system with plastic beads for a 4D CT experiment simulating the Brazil Nut effect.

Nikon CT @ University of ManchesterOne standalone XT H 225 and two X-ray walk-in rooms give researchers unique flexibility in scanning components of various sizes and densities for research and commercial projects.

• A great range of component scale enables researchers to scan endless types of objects

• Interchangeable sources make the CT systems highly flexible for unique research and commercial projects

• Large walk-in bays and customs setups are perfect for customising for IPC and time-lapse studies

The Henry Moseley X-ray Imaging Facility helps develop world leading research, and is open for academic and commercial services. For more information, please contact: hmxif.enquiries@manchester.ac.uk.

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Stoneridge is a global designer and manufacturer of highly engineered electrical components and systems for commercial vehicles, automotive, off-highway and agricultural vehicle markets. These parts are the core of mechanical and electrical systems and improve overall vehicle performance in areas such as emissions control, fuel efficiency, safety and security.

Founded in 1965, Stoneridge has a vast amount of experience in this field and will have a vital role to play in the future of automotive manufacture. With the developing trend of autonomous vehicles, and the constantly increasing emphasis on the environmental aspect of vehicles, the activities at Stoneridge now and in the future are of growing importance. Stoneridge manufactures application-specific switches and actuators, sensors, security alarms, vehicle tracking devices and monitoring services which are subject to extensive testing and quality control. These items are critical to the safety of road-users and vehicle security. Especially with autonomous driving on the horizon, component failure is not an option.

Stoneridge in Tallinn, Estonia, recently installed the Nikon ALTERA CMM with LC15Dx laser scanner in its test laboratory to take inspection of automotive components to the next level. The Laser scanner provides many advantages including complete visualisation of parts, non-contact measurement for delicate components and repeatable measurements.

Automotive supplier identifies mystery error using Nikon laser scanner

Case study

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Extensive environment simulation testingTimo Jakimainen is the Senior Engineer in the test laboratory at the Stoneridge factory based in Tallinn, Estonia. He is the primary CMM operator in the laboratory and has been sharing his knowledge by training his colleagues in use on the latest installation. Timo introduces the test laboratory with a tour, demonstrating the broad range of equipment which is used to assure absolute top quality of components for all clients. In manufacturing automotive components, there is a growing emphasis on the quality of components. They are expected to have a longer life cycle and need to meet tougher demands. Therefore, before mass production, all components are put through their paces. From key fob buttons requiring at least 1,000,000 clicks, water submersion and dust-tight testing for IP class ratings, to extreme temperature shifts and cabin vibration simulation – the test laboratory leaves no stone unturned.

Timo says that the test laboratory started out with basic equipment and testing facilities, but has continued to grow to meet the demands of clients. However, the growing capabilities of the Test Laboratory had left the measurement equipment behind.

To complement the extensive testing laboratory equipment at Stoneridge a multi-

sensor CMM was the most recent investment. Previously, an older CMM was used, but its repeatability proved to be a hindrance. The slow system offered low quality results with poor data analysis. This meant that measurement and inspection work was often sent back to the supplier.

A new CMM was required for taking control of inspection and measurement, thus saving vast amounts of time. However, the search for a CMM led the decision makers to discovering the possibilities and benefits of laser scanning.

Relying on suppliers for measurement and inspection after testing with limited access to quality inspection tools, Stoneridge relied on suppliers’ measurement capabilities to provide feedback and results.

Anti Laas, Mechanic Design Engineer at Stoneridge says, “Since every measurement is money, we ask suppliers to do it, but they take a lot of time. They have their own projects, like measuring for serial production… so, it’s a long queue. You have to wait a long time, and we no longer have that time”.

The benefits of owning a multi-sensor CMM, or any comprehensive measurement systems were previously unknown for Stoneridge. For the engineers, the cost of a top of the range system seemed too much for what

use they would get from it. At that time, sub-contracting the measurement tasks back to suppliers was the best value for Stoneridge. However, as operations grew and it was no longer productive to be sending all measurement work out of the factory, the decision was taken to research the metrology market for a suitable solution.

Learning about the laser scanning capabilitiesTimo Jakimainen led the search for the new equipment, alongside his colleague Anti Laas. Although the initial search was to find a modern, accurate and productive CMM, it was Anti’s knowledge of laser scanning that opened up a whole new range of possibilities. Anti explains that with a CMM and touch probing, data isn’t always useful. You don’t have the whole picture, you are basing what you know on a few points, a few dimensions. In some cases, information in this format can be manipulated to provide the results required. Therefore, due to the lack of full 3D data, it fails to reveal problem areas of a component, often hiding or obscuring the bad areas of a part.

According to Anti Laas, “If you’re only taking a few dimensions, you don’t know what is going on in another area of the part. With a laser scanner, it gives you a more holistic view… the full picture”.

The LC15Dx scans the plastic automotive assembly.

“ Creating part programs is very easy. The program will last for as long as the part is in production. The program is always there. Ready to use.” Timo Jakimainen, Senior Engineer at Stoneridge.

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Image 2 illustrates the problem which the team at Stoneridge found with using a CMM and how it was solved with the introduction of a laser scanner. This part failed tests multiple times, and the measurement results returned to show there were no problems, and it shouldn’t be failing. Still it failed. For the purpose of this component, the contacts were not required to be measured. The points used for measuring were around the base, but there were no problems found while the measurements added up. It wasn’t until the introduction of the laser scanner, that they noticed the issue. With laser scanning, you immediately see the whole picture. You immediately have visual representation of the part – as a whole – and you can see clearly where the problem is.

Timo summarises by saying, “with a laser scanner, you have much more transparency”.

What are the benefits of laser scanning?After initial project analysis and budgeting, some engineers weren’t convinced of the return on investment of using a CMM. It wasn’t until Stoneridge’s meeting with Nikon, that they began to understand the interesting benefits that laser scanning on

a multi-sensor CMM could bring to the test laboratory.

Timo recalls the occasion when he travelled to Belgium to meet with the Nikon Metrology team. He explains that the round trip included a selection of other CMM/laser scanner providers. The meeting with Nikon showcased the benefits of laser scanning, including the ability to scan dark or metallic reflective surfaces with effective pointcloud acquisition.

With a much clearer picture of how the technology works, how reliable it has become, and what it could offer for the test laboratory, Timo and Anti knew that laser scanning technology was what they required. The optical image and data quality of the Nikon Metrology system for scanning the widest variety of parts is world class. Nikon’s state-of-the-art scanning technology sets it apart from the closest competitors as it provides the best scanning experience available today.

So, how does the new system fit in with activities in the Test Laboratory?Mechanic Design Engineer, Anti Laas sets forward the three main benefits of the Nikon LC15Dx, its speed, accuracy and 3D visualisation.

“Graphical reporting is a big benefit, you can simply show the supplier an image and ask about specific areas, and what can be done about it”, he says.

Timo adds, “The majority of measurements are done like this now. The laser scanner offers much more transparency”.

He continues to explain the broad spectrum of applications for the technology at Stoneridge. “We use it (the multi-sensor CMM) for a lot of things. Not just one field, basically from day one of development to serial production, and ten years ahead, in quality issues this machine will constantly be used. Quality, development, design verification/prototyping, validation etc.”.

The Nikon system is useful for many departments and is used for a vast range of applications. One which is very important is ‘preventative measurement’. For this, a reference measurement profile will be created for a part which is mass-produced. The purpose of this test is to prevent line stoppages. With the measurement profile, they can take a sample from each batch, or once per month to closely examine the part and look for anything that isn’t quite right. If anything is found, they can contact the supplier and ask them to correct the issue, before it becomes a problem.

Installation and trainingThe ALTERA 10.7.6 CMM with LC15Dx laser scanner was installed in January 2017, followed by an intensive training. Since then Timo has already created many programs and has had a large amount of success using the

This part continued to fail tests and the problem could not be determined until the introduction of the LC15Dx.

Graphical reporting is a big benefit at Stoneridge as it makes discussions about errors much simpler.

“ If you’re only taking a few dimensions, you don’t know what is going on in another area of the part. With a laser scanner, it gives you a more holistic view… the full picture.” Anti Laas, Mechanic Design Engineer at Stoneridge

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machine, but he still believes he can learn more about the machine and reap more benefits.

“Creating part programs is very easy”, says Timo. “The program will last for as long as that part is in production. The program is always there, ready to use”.

Previously the test laboratory was responsible for many tasks, from the measurement, to analysing and presenting results. Timo jokes, that all he needs to do now is scan in a global comparison and hand over to Anti. With the offline dataset to analyse every aspect of the part, he now saves a lot of time for his colleague.

What results have been seen so far?Some immediate benefits that have been seen at Stoneridge include the non-contact measurement. Rubber key pads for controllers, and electronic key fobs were very difficult to measure before the introduction of the laser scanner. Timo explains that they did what they could, but had to explain to clients that they couldn’t guarantee the measurements were absolutely accurate. By applying pressure, the touch probe would deform the rubber part, making the measurement void. However with the LC15Dx, it measures not only with a contact free laser and camera system, but from a short stand-off which enables the scanner to access hard-to-reach areas and visualise them with high accuracy, comparable and closely correlating to touch probing accuracy.

The introduction of the Nikon Metrology system has introduced other opportunities aside from the normal line of work. Something which the engineers in the test laboratory are looking into is measurement before and after testing. Some of Stoneridge’s clients already demand this. After going through its standard tests for IP class rating, or other environment simulators such as vibration and extreme temperatures the components will be subject to testing to see how the part has changed.

The capability of the system is encapsulated by the amount of requests from outside of the company. Stoneridge has also been working with the local university – which also owns a Nikon system for referring people for one-off or sub-contract inspection. More and

more requests are beginning to come in from Estonian companies to use the Nikon system.

However, for both Timo and Anti, they agree that one of the most useful functions for what they need is the full visual colour comparison. With all of the data available, it can be

represented in easy-to-interpret reports, saved and shared at the click of a button. If ever there are problems, or something that went under the radar, they can bring up the report, check it and share it.

Rubber key pads for controllers and electronic key fobs were very difficult to measure before the introduction of the laser scanner.

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The metal additive manufacturing company Sintavia adds Nikon Metrology CT to its state-of-the-art facility in Florida, USA to further control the additive manufacturing process.

Sintavia gets the inside track with micro-CT

Additive manufacturing is making enormous waves throughout every industry. The technology allows ultimate flexibility in creating the most intricate and complex features ever designed for manufacturing.

As the technology establishes itself as a vital manufacturing tool for producing ultimately efficient components, companies such as Sintavia have to be ahead of the game. Sintavia is the global leader for independent metal additive manufacturing in industries with precision applications. The additive manufacturing market is constantly growing, and in this climate, Sintavia sets itself apart by providing a full design through-production contract manufacturer.

Based in Davie, Florida (USA), Sintavia’s portfolio includes a whole range of equipment. The facility features 8 high speed additive manufacturing machines, as well as post-processing equipment, powder, metrology and mechanical testing laboratories, and various quality assurance tools. Using powder bed fusion (PBF) and electron/laser beam melting, Sintavia is currently manufacturing with Inconel 718, Inconel 625, Aluminium, Titanium, Cobalt Chrome, Stainless Steel, and other proprietary powders.

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To understand the process, is to control the processAs Sintavia sets itself apart with its beginning-to-end manufacturing, its biggest asset is having full and total control of the additive manufacturing process. Without complete control, you do not have complete understanding of the process.

Brian Neff, Sintavia’s CEO, summarizes this by stating, “If you don’t understand and control the process, you won’t build what you want to build”.

Typically, both traditional and additive manufacturing faults include microscopic voids and gaps within the structure. These voids can cause stress fractures and reduce the longevity of a component’s lifecycle. To produce the most reliable components for a customer, these must be identified and eradicated.

Additive manufacturing allows for very special design features such as conformal cooling inserts, functional integration, complex geometries, lattice networks and hollow members to be produced. These internal designs can only be inspected with CT scanning. “There are thousands of metal AM machines in place globally with just as many people if not more still figuring the process out,” says

Brian Neff. “We’re making it a mission to work with our customers to develop optimal parameters for their builds. If you don’t understand and control the process, you won’t build what you want to build.”

Though estimates vary, researchers agree that the market is growing:• Consulting firm IDC – global spending on

desktop and industrial 3D printers hit about $11 billion in 2015 and is forecast to reach $27 billion by 2019

• MarketsandMarkets – 3D printing will experience a 30% compound annual growth rate (CAGR) and reach $30 billion by 2022

• PwC – 52% of manufacturers in 2016 expected 3D printing to be used in high-volume production in the next three to five years, up from 38% in 2014

Amidst such growth numbers, Sintavia is doing much more than promoting its 3D printing capabilities – it is positioning itself as a full-service, design-through-production provider. In addition to eight high-speed powder-bed metal printing machines, Sintavia’s full post processing department includes a hot isostatic press, vacuum heat treatment, CNC machining, EDM equipment, and destructive and non-destructive testing capability.

“Working with our customers to develop optimal parameters for builds demands

nothing less than total process knowledge and understanding,” Neff says. “Sintavia is able to optimize parameters, serially manufacture, and audit quality much faster than any of our competitors.”

Fast inspections & full controlPreviously, Sintavia relied on external measurements. It was very successful for line-of-sight, however not so much for capturing passageways and chambers produced through additive manufacturing. Sintavia decided to invest in the latest CT scanning technology to achieve the desired level of quality control required for precision industries.

As a manufacturing company that excels in all aspects of the process from start to finish, it was obvious that Sintavia needed to invest in a CT scanner. Other companies often outsource the CT scanning inspection and verification but as a global leader in independent metal AM, the final decision was taken to invest in the technology. To have in-house CT scanning capabilities enables quick inspections and allows full control over the quality of product.

As an independent metal AM company, Sintavia handles a lot of varied requests and requirements for the components it produces. Throughout aerospace, automotive, and oil & gas industries, Sintavia produces a broad

“ Sintavia is able to optimize parameters, serially manufacture, and audit quality much faster than any of our competitors.” Brain Neff - CEO at Sintavia

The micro-focus CT system allows to visualize individual metal powder particles.

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spectrum of parts for various companies. There is an enormous amount of responsibility on Sintavia to manufacture components without error, and CT is the only way to gauge if parts are being manufactured correctly.

Sintavia technicians understand the importance of inspection and process verification in quality control. Manufacturing standards are the highest in aviation, Neff says, driving the need for a quality control process that is robust and repeatable to clearly demonstrate and improve part quality. It is essential to know whether voids or inclusions are present, how large they are (both individually and in total), where they occur – and also whether the dimensions of the part conform to those of the design.

In such cases, X-ray computed tomography (micro CT) is a powerful answer, and Sintavia has installed a 320 micro-focus CT system from Nikon Metrology. By converting 2D pixels to 3D voxels, supplying a full 3D density map of the samples, micro CT gives all this information in an easy-to-read visual format.

Better insights, reduced costs with Nikon CTWith traditional manufacturing processes, a few radiographs at specific orientations can suffice. But with additive layer manufacturing (ALM), the whole part needs to be inspected,

particularly for aerospace parts with stringent tolerances. Inspection must include:• Powder residues blocking channels• Defects (voids & inclusions) –porosity,

contamination, cracking• Departure from the CAD model –

dimensional analysis, wall thickness measurements, warping

Micro CT can determine the cooling and flow channels built in by the ALM process to an accuracy of 50μm to 100μm (depending on acquisition parameters). Micro-CT can find defects within samples down to a resolution given by the number of pixels across the detector.

Given a sample 100 mm across, and a detector 2,000 pixels across, the limiting resolution would be 50μm. Resolution is also limited by the focal spot size of the X-ray source, which may range from 80μm for high energies down to less than 1μm for low energies.

The size of sample that can be scanned with CT depends on the material it is made of and the energy of the X-ray source, measured in kilovolts (kV). Larger lower density samples can be scanned, as can smaller higher density samples.

Micro CT is now much faster and more suitable for production-line use and CT scanning of similar parts can be automated

for loading and unloading. Scan times down to a few tens of seconds per part are possible. Nikon CT offers:• Better insight into the inside of ALM parts• Faster optimization of ALM prototyping,

production processes• Quality control, higher confidence in

incoming, outgoing parts• Reduced costs by avoiding destructive

testing

Striving for total understanding in anything is the process of the scholar, the visionary, and the insightful. With the rewriting of the manufacturing rules book that 3D printing brings, X-ray CT is a powerful partner for non-destructively assuring geometrical and tolerance quality control.

CT analysis is extremely versatile : external/internal dimensional inspection, compare to CAD model, sectioning in any direction, material and void analysis, etc

A part is placed on a rotate stage and 2D X-ray images are taken at incremental angles. Then the 2D X-rays images are reconstructed into a 3D model.

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The LC15Dx laser scanner is irreplaceable for analysis of 3D-printed implant screw holes and surfaces

Improving quality of treatment for patients

Quality assurance is vital for accurate production of patient-specific joints and prostheses, therefore Baltic Orthoservice uses a multi-sensor CMM and laser scanner in conjunction with a micro-CT system. The multi-sensor CMM is used for fast surface and screw hole inspection of the 3D-printed implants. The XT H 225 CT system is used to guarantee internal structure quality and geometrical accuracy between CAD implant model and manufactured implant. The combination of these technologies enables Baltic Orthoservice to achieve the best accuracy and highest quality for a wide variety of medical devices.

The core business of Baltic Orthoservice is manufacturing 3D-printed patient-specific implants, endoprosthesis and surgical guides. Operating in the medical industry, the Research and Development (R&D) department is responsible for product development, prototype geometry investigations, quality assurance and final quality control.Paulius Lukševicius is the Engineer of Mechanics at Baltic Orthoservice, he explains, “3D printing is a complicated technology and has a big variation of processing parameters, consequently predicting the quality and geometry of printed objects is quite a challenge.

Patient-specific implants are a ‘pre-planned’ treatment solution, which basically means that the whole surgery must be ‘pre-planned’ virtually, so that the implant can simply be put in place. In order to meet the virtual plan, it is vital to be 100% sure that implant geometry is exactly the same as the designed CAD model and the screw holes are milled at a high accuracy. To fulfil these goals, we use a variety of quality assurance equipment, including a multi-sensor CMM and micro-CT.

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The ALTERA CMM with LC15Dx laser scanner is irreplaceable when we need to perform fast quality assurance check-ups after each manufacturing and post-processing stage, especially to check spherical surfaces, bearing surfaces and screw hole angles”, Paulius states.

3D-printing enables production of implants with anatomically adapted surfacesPictured above, is the patient-specific acetabular implant GIGIT. Implants such as this are only used for complex hip joint cases - severe acetabular defects (W. G. Paprosky 2A-3B), or pelvic discontinuity. This implant is used to help recreate the anatomy of a hip joint and to restore its functions.

Milda Jokymaitytè, Clinical Engineer at Baltic Orthoservice explains, “Unlike standard modular implants used to treat severe clinical conditions, patient-specific hip implants are designed as a single device with anatomically adapted surfaces. This eliminates the risk of instability, and adapts the implant to the bone rather than the bone to the implant”. A major benefit of this procedure is that during surgery, there is no need to shape the bone in order to adapt it to the implant or use bone cement, meshes

and augments to fill the bone defect. Patient-specific implants are designed using virtual anatomical bone models which are obtained from medical computed tomography (CT) scan of a patient.

For manufacturing patient-specific implants, Baltic Orthoservice uses DMLS technology (direct metal laser sintering). The implants then undergo a variety of post-processing steps, including heat treatment, surface polishing and milling for screw holes.

There are a number of medical device standards and regulations which must be met, which is why it is paramount for products to be of ultra-high accuracy. With such fine tolerances and strict standards to meet, the post-processing stages are repeated until the physical implant matches the desired virtual model exactly and quality assurance measures are taken following each step.

After each post-processing stage, the LC15Dx laser scanner is able to quickly show how the physical part matches the virtual model. Milda explains that “the LC15Dx on the ALTERA CMM is great for checking geometrical accuracy of implant screw holes at each transitional process”

Developing a Quality Control Laboratory with top quality equipmentSince investing in additive manufacturing technologies in 2012, Baltic Orthoservice has also assembled a portfolio of quality assurance equipment. The goal is to guarantee the absolute best quality of product for its patients, and make patient specific implants more readily available.

“We, as manufacturers, must ensure the best quality of our products. Therefore we decided to develop the Quality Control Laboratory in our facilities and invest in high-quality equipment”, Paulius explains. “Alongside the multi-sensor CMM, Baltic Orthoservice therefore also uses a Nikon Metrology XT H 225 micro-CT system”.

Milda explains that laser scanning and micro-CT serve two different purposes and both excel in different areas. “The ALTERA CMM with LC15Dx is great for inspecting features and surfaces of bigger-sized implants, such as acetabular implant, for standard products like osteosynthesis plates and for standardized elements in patient-specific implants, i.e. screw holes or spherical shapes.” Milda continues: “The micro-CT system is a vital tool for non-destructive analysis of the

“ The CMM is irreplaceable when we need to perform fast quality assurance check-ups after each manufacturing and post-processing stage, especially to check spherical surfaces, bearing surfaces and screw hole angles.”Paulius Lukševic ius – Engineer of Mechanics

The patient-specific acetabular implant GIGIT.

16

internal structure and geometry for additive manufactured components”

For Baltic Orthoservice, the systems are used in tandem to complement each other. By using both of these technologies, Baltic Orthoservice can guarantee absolute accuracy – as is demanded in the medical industry - and to maintain its USP: producing patient-specific implants.

The highest accuracy: Nikon Metrology offers the complete solutionAs the Quality Control Laboratory was a new project to supplement the additive manufacturing facilities, there were no previous systems to be replaced. Baltic Orthoservice knew what was required and compared the best technologies on the market to find the right solution.

Paulius discusses that, “The first requirement was to have the capability to scan parts made from different types of materials. The working area was also important, but most importantly - accuracy”.

The final choice was between Nikon Metrology and another leading competitor. To suit the needs outlined by Baltic Orthoservice, the Nikon Metrology laser scanner proved to be the outstanding solution. Paulius explains that the competitor was rejected due to “differences in laser scanning probe”.

He cites the longevity and accuracy to be a major factor in the decision with the moving parts in the competitor’s probe to be a concern for potential complications and expensive maintenance.

A key advantage of the Nikon Metrology LC15Dx is its ability to scan reflective and multi-material surfaces thanks to the unique ESP technology. This means it maintains accuracy, speed and data quality by intelligently adapting the laser settings for each measured point in real-time. Its accuracy has a probing error comparable to that of tactile inspection (1.9 µm), and data collection speeds of 70,000 points per second. By maintaining such high standards when scanning difficult surfaces, this makes the LC15Dx an incredibly powerful tool for inspecting complex parts in the medical industry.

Ultimate quality assurancePaulius concludes by discussing the results so far, “the Nikon solution offers better knowledge of what we are manufacturing, gives better precision and understanding of the 3D-printing errors and deviations. This means we achieve the best product quality

and avoid the risk of implant failure during the operation, implants with Nikon quality assurance are more reliable and it is easier to prove their value”.

It’s clear to see how Nikon Metrology inspection solutions have played an important role in the production of 3D-printed medical implants. This has also been recognised by other manufacturers. Paulius explains, “very often our Quality Control Laboratory gets inquiries from other manufacturers in medical and industrial fields to perform standard part geometry inspection for them”.

Whilst both the ALTERA with LC15Dx and XT H 225 have significant individual benefits, it is the combination of the two solutions that works so well for Baltic Orthoservice. The R&D team has a Quality Control Laboratory that possesses the best tools to cover all angles. So, it is with good reason that Baltic Orthoservice has absolute confidence in the quality of all final products. Whatever the case tasked with, all solutions will be made-to-measure with ultimate quality assurance.

By maintaining such high standards when scanning difficult surfaces, this makes the LC15Dx an incredibly powerful tool for inspecting complex parts in the medical industry.

The use of the micro-CT system XT H 225 at Baltic Orthoservice is elaborated in a dedicated case story. 'Patient-specific implants made affordable' can be found at: https://www.nikonmetrology.com/en-gb/services-support/download-center/case-studies.

17News I Volume 13

Nikon Metrology & Roush Yates engines announce tech partnershipMOORESVILLE, NC, February 22, 2018 – Roush Yates Engines and Nikon Metrology (Brighton, MI) announced a multi-year partnership program, demonstrating Roush Yates Engines’ commitment to partnering with the best-in-class companies. With over a 100 years of experience Nikon provides world-class precision equipment and metrology solutions to the manufacturing, aerospace, automotive and medical fields.

“We are proud to have Nikon as our new partner,” said Doug Yates, President & CEO, Roush Yates Engines. “We are always looking for partners that are at the top of their class. The Nikon brand is one built on innovation and quality. Their premium CMM equipment is world-class and a perfect fit for Roush Yates Engines.”

“We are very excited to be partnering with one of the most respected engine builders in the motor sports industry,” adds Andy Stults, Marketing and Communications Manager at Nikon Metrology. “Roush Yates Engines provide the highest performance and most reliable engines for teams at the racetrack, as their winning record proves. The parts in their engines require the utmost precision

and quality in order to meet performance demands. We greatly value this partnership with Roush Yates Engines and are proud that our technology is helping ensure they continue to meet their need for high-performance, high-reliability components.”Nikon’s LC15Dx Laser Scanner provides a unique 3D visualization of dimensional quality using Color Mapping. In addition, Nikon’s unique ESP3 technology maintains accuracy, speed and data quality by adapting the laser settings in real-time, improving efficiency and part quality data accuracy. “These advanced capabilities allow our team the ability to measure and analyze a larger array of parts, each with varying geometry and materials, with a single piece

of equipment,” said Chad Johnson, Roush Yates Engines Quality Manager.“In addition, Nikon’s CMM Manager software, provided for all of Roush Yates Engines CMM’s will save considerably on programming time,” Johnson added.

The iNEXIV Vision System was also added to the Roush Yates Engines line-up of inspection equipment. This CNC video measuring system is ideal for both large and tall mechanical parts and uneven surfaces, in addition to providing a broader XYZ measurement range, which is ideal for analyzing complex geometry engine components.

Nikon’s LC15Dx Laser Scanner provides a unique 3D visualization of dimensional quality using Color Mapping. “This allows our team the ability to measure and analyze a larger array of parts, each with varying geometry and materials, with a single piece of equipment,” said Chad Johnson, Roush Yates Engines Quality Manager. Nikon’s unique ESP3 technology maintains accuracy, speed and data quality by adapting the laser settings in real-time. This improves efficiency and part quality data accuracy.

Case study

18

Alternatives to a replacement video measuring machine were evaluated, such as table-top varieties of measuring cameras and coordinate measuring machines. Even the possibility of subcontracting first article inspection to an external bureau was considered. However, it was decided that established in-house procedures would remain, so Robert Brown, owner and Managing Director of SCL and James Pickett, Quality Engineer, set about sourcing the best equipment for their requirements, productivity and affordability being key.

Three potential suppliers were identified, but Nikon Metrology was always the front runner. Mr Pickett said, “Technical support was there from day one, from the enquiry right through to installation and commissioning of the video measuring machine in January 2017.

“Moreover, the machine was around half the price of the other main contender, so it was very affordable and return on investment will be rapid.

A Nikon iNEXIV video measuring machine has successfully taken over quality control of printed circuit boards (PCBs) at Stevenage Circuits Limited (SCL) after the graphics card failed in a piece of similar, decade-old equipment from another supplier. The new iNEXIV VMA4540 is used virtually continuously for 2-D optical coordinate measurement of machined features and copper tracks. It underpins not only first article inspection of boards and printed reports for customers, but also process control in the drilling, etching and routing departments.

Case study iNEXIV video measuring system accelerates PCB inspection

James Pickett, Quality Engineer, Stevenage Circuits Limited, operating the Nikon Metrology iNEXIV VMA4540 video measuring machine.

19News I Volume 13

“We were also influenced by Nikon’s name as a manufacturer of top quality cameras and optics. The iNEXIV was best in class and the clarity of the optics was second to none. You could tell the difference between their equipment and a competitor’s during trials we carried out at both companies.

“Another positive factor was the VMA4540’s adaptable software. In addition, the support from Nikon Metrology’s UK team was deemed to be the best fit, as the company had a demo centre and a large team that was very knowledgeable about the system.”

Established in 1971, SCL is the only European manufacturer with in-house capability for design and production of all four principal types of PCB. The single- and multi-layer boards are manufactured to a minimum standard of IPC class 2 and are supplied in high volume, small batch or prototype quantities to PCBA (assembly) houses, where electronic components are mounted. Heat sinks are the only additions to the boards before they leave the Stevenage factory, bound for customers in over 40 countries. Radio frequency boards account for a majority of output and around one-third of total production is destined for the medical industry, while the space and military sectors are also regularly supplied.

Rapid PCB turnaroundThe manufacturer prides itself on the supply of PCBs in short lead leadtimes times, three to five days turnaround being the norm from order to delivery. Around half a dozen new jobs are progressed through the factory on a typical day, with up to 15 boards requiring in-process checking.

The company’s quality control department is therefore kept busy from 7.00 am until 7.00 pm, five days a week and sometimes on Saturdays. It means that the Nikon video measuring machine is required to work almost non-stop and is used not only by Mr Pickett, who programs the machine, but also by machine operators in the various production departments.

The VMA4540 is called upon repeatedly during the life cycle of each new job. As 95 per cent of SCL products only need positional and dimensional measurement of profiles, such as board periphery, cut-outs and drilled holes as well as copper tracks and pads, the machine is used exclusively in 2-D mode. Its ability to accept a laser or touch probe is not needed and neither is its 3-D measuring capability derived from repeated focusing down sloping features.

Reliability of first article inspection at each stage of a board’s manufacture is crucial, as the results are used to control each process. Inaccurate or inconclusive readings would negatively impact production.

Repeated visits to the VMA4540After the required number of layers has been bonded together to form a board, the first operation is CNC drilling using data sent from SCL’s CADCAM department, which takes into account stretching or shrinkage during subsequent stages of manufacture. The first-off from each batch of typically 25 is checked at this stage on the video measuring machine against the corresponding Gerber file, a vector format for 2D images used as standard in PCB industry software. Alternatively, if there is time, Mr Pickett converts the data to DXF, as it is easier to manage. The Nikon Metrology iNEXIV control can import both file formats and work with them natively.

If any discrepancy is found, for example a hole is not present due to a broken drill, the measuring machine stops and flags up an error. An out-of-tolerance hole diameter or position, which typically need to be within ± 50 µm and ± 100 µm respectively, results in a similar error message. Normally, the PCB

James Pickett, Quality Engineer, Stevenage Circuits Limited, operating the Nikon Metrology iNEXIV VMA4540 video measuring machine.

Nikon Metrology iNEXIV control screen running AutoMeasure software.

“ We have been delighted with the performance of the iNEXIV machine, which is spot-on in its measuring capability.”James Pickett, Quality Engineer, SCL

20

passes the inspection and a system report is prepared, although not normally printed out as it is rarely required by the customer. The historical data can however be interrogated for troubleshooting purposes if a problem subsequently occurs with the board.

The next stage of production is etching of the tracks using laser direct imaging. Track widths are important, especially on radio frequency boards, and have to be typically within 50 µm to 100 µm, ± 10 µm. A sample scan is made on the VMA4540 across an area of the first-off and compared with the CADCAM data to ensure that track measurements including their positions are within tolerance.

After visits to the solder resist and plating departments, the PCBs find their way to the routing shop where CNC machines trim the boards to their final size and produce internal cutouts as stipulated in the CAD drawing. Again, the first-of is checked on the VMA4540 against the Gerber / DXF file. The finished product is now inspected in its entirety and it is this dimensioned, first article inspection report that SCL’s customers normally require. Results are entered automatically by the Nikon Metrology software into a test report template that populates an Excel spreadsheet. It is linked to the relevant CAD drawing and given to the customer, as well as being archived for future reference.

Between 10 and 20 per cent of final boards are evaluated in this way on the video measuring machine. In the case of smaller PCBs, up to a dozen or more can be on the table at the same time and the software steps and repeats to check the entire panel in a single cycle, very rapidly.

Mr Pickett concluded, “We have been delighted with the performance of the Nikon machine, which is spot-on in its measuring capability, particularly when inspecting smaller features that our other equipment could not do in a similar time frame.”

A panel of eight PCBs being inspected on the VMA4540 in a single CNC cycle.

Measured results from the VMA4540 are output automatically into a template in an Excel spreadsheet to speed report preparation for SCL’s customers.

21News I Volume 13

IXYS UK Westcode (www.westcode.com), part of the global power semiconductor manufacturer, IXYS Corporation, is investing in its Chippenham, UK factory to manufacture a new range of power semiconductor devices, which will be marketed alongside the company's long-established Press-Pack Capsules. Nikon Metrology (www.nikonmetrology.com) was chosen to supply the all-important X-ray equipment for checking the quality of the reflow soldering process during production.

Power semiconductor devices are used for switching high currents and voltages and are widely used in the rail, wind turbine, mining and petrochemical sectors. Press-Pack capsules are clamped together under high pressure to achieve the required electrical rating, whereas isolated power modules use integrated circuit on DCB (direct copper bonded) substrate technology. The Nikon Metrology XT V 160 is needed because the reflowed solder, which attaches the chips to their contact pads, must be continuous with a controlled level of voids and X-raying is the only way to see if these conditions have been met.

Fiona Lambert, Process Engineer at IXYS UK Westcode commented, "I previously used a smaller Nikon 130 kV X-ray quality assurance (QA) system when I worked at an electronics company in South Wales, so I knew how easy their equipment is to use. After reviewing what else was on the market, it was clear that their more powerful 160 kV model would best suit our application, which involves penetrating thicker and higher density materials to observe solder coverage.

Case study

Nikon Metrology XT V 160 checks power semiconductor devices in production line

Insight into the Inside X-ray inspection of solder quality

22

"What I particularly like about the Nikon system is the easy access to the large stage, which allows me to place several, quite large components on it at the same time. The machine is fast in operation and the stage is easy to manipulate in multiple axes, so tilting, rotating and positioning as well as zooming the image on the screen is rapid. You can see everything clearly, as the image is high resolution. The software is also user-friendly and even works out automatically the percentage of voids in the solder, required to ensure the product meets rigorous specifications.”

Two-step X-ray inspectionX-raying is carried out at two stages of manufacture. The first is after the chips have been placed on the blank DCB substrate and reflow soldered. After six built substrates have been electrically tested and soldered onto a 5mm thick aluminium-silicon-carbide baseplate, the whole assembly is X-rayed again.

The XT V 160 inspects the assembly reliably, even without Nikon Metrology's optional X-ray laminography software or CT (computed tomography) add-on. Features of the machine that assist in completing the task efficiently include its 20 Watt target power rating, focal spot size between 1 µm and 10 µm depending on power output, up to 36,000x system magnification and the high image quality provided by a Varex 16-bit flat panel. Having such fine resolution allows easy distinction between geometrical shapes and the amorphous voids.

Multiple uses: X-ray systems inspects quality of incoming materialsWhile the X-ray machine was installed specifically for DCB inspection, its presence on the Chippenham site has proved beneficial for verifying the quality of bought-in materials. On one occasion, a supplier disputed that there was a high incidence of solder blockages in a consignment of delivered coolers that form part of Press-Pack IGBT stacks. A simple analysis using the XT V 160 provided irrefutable evidence and resulted in the prompt arrival of a replacement batch.

Open-tube X-ray source design reduces maintenance costAn additional advantage of X-ray technology from Nikon Metrology is the stability of output due to the microfocus spot source and advanced image processing capabilities, essential to avoid degradation of image quality. Focus of the electron beam is maintained by a computer-controlled, electromagnetic lens that ensures the target does not overheat whilst maintaining a micron spot size, even at high kV settings.

Although a high power machine, the XT V 160 is of open-tube design. As part of planned maintenance, replacement of the electron beam-producing filament can be scheduled a couple of times per year for a cost of a few pounds. Filament replacement takes minutes, so downtime is short. A sealed tube, on the other hand, will last for a couple of years but can stop working without warning, perhaps at the worst possible time for the user. The manufacturer then has to be called in to renew the tube at a cost of many thousands of pounds and the machine is down for days.

ConclusionIXYS UK Westcode's inspection of power semiconductor devices will increase over the coming years. With one or two products per batch to be X-rayed for QA, the Nikon Metrology machine will be in constant use once the process has been finally established.

“ The machine is fast in operation and the stage is easy to manipulate in multiple axes, so tilting, rotating and positioning as well as zooming the image on the screen is rapid.”Fiona Lambert, Process Engineer at IXYS UK Westcode

Fiona Lambert operating the Nikon Metrology XT V 160 X-ray inspection system. The large manipulator stage allows to inspect multiple parts in a single batch.

23News I Volume 13

Nikon Metrology delivers 1,000th 160 kV X-ray source for electronics inspection systems

Since the manufacture of X-ray inspection machines began at Nikon Metrology's Tring, UK factory in 1987, 1,000 Xi sources with an internal X-ray generator have been designed, produced and integrated into the company's XT V systems, in addition to numerous other sources for the XT H range of X-ray and computed tomography machines.

The latest Xi source has been incorporated into an XT V 160 electronics inspection system that is supporting quality assurance of power semiconductor device production at IXYS UK Westcode, Chippenham, UK. The X-ray inspection machine is being used to check whether the reflowed solder that attaches integrated circuits to contact pads on the direct copper bonded substrate boards is continuous, with a controlled level of voids.

The 160 kV Xi source is of integrated construction, unique to Nikon, which eliminates the need for a traditional, high voltage cable connecting the X-ray generator to the source. Maintenance costs are therefore lower, as such cables can be prone to failure and need regular maintenance.

As with all Nikon sources it is of open-tube design, giving low cost of ownership. As part of planned maintenance, replacement of the electron beam-producing filament can be scheduled during the year for a cost of a few pounds each time. Filament replacement takes minutes, so downtime is short.

By contrast, a sealed tube will last for a couple of years but can stop working without warning, perhaps at the worst possible time for the user. The manufacturer then has to be called in to renew the tube at a cost of many thousands of pounds and the machine is down for days.

Fiona Lambert, Process Engineer at IXYS UK Westcode commented, "I previously used a smaller Nikon 130 kV X-ray quality assurance system when I worked at an electronics company in South Wales, so I knew how easy their equipment is to use.

"After reviewing what else was on the market, it was clear that their 160 kV model would best suit our application. The Xi source allows high resolution to be maintained at high powers, which we need to penetrate a thick aluminium layer to evaluate solder quality.

"What I also like about the Nikon system is the easy access to the large stage, which allows me to place several, quite large components on it at the same time. The machine is fast in operation and the stage is easy to manipulate in multiple axes, so tilting, rotating and positioning as well as zooming the image on the screen is rapid.

"The software is also user-friendly and even works out automatically the percentage of voids in the solder, required to ensure the product meets rigorous specifications.”

WATCH THE VIDEO

The XT V 160 at IXYS UK Westcode contains the 1,000th Xi X-ray source to be manufactured at Nikon Metrology's factory in Tring, UK.

A video of Fiona Lambert talking about the advantages of the Nikon Metrology XT V 160

can be accessed here.

24

Lukov Plast is a leading Czech producer of plastic parts and sub-assemblies. With many years of experience, this dynamic company specialises in the development and manufacture of plastic electronic components for the automotive industry.

The core business activity is producing plastic parts, components and electrical assemblies. Often used in the vehicle interior, air conditioning systems and control units, these parts are manufactured by injection moulding. The ever increasing customization and complexity of parts is taking on a high demand of quality and requires a palette of flexible and adaptable inspection equipment.

The fast paced automotive industry is already approaching the next milestone of autonomous driving. Whilst the

sector evolves in this way, there is an increasing demand for not just life-critical components, but all components to be of the highest quality.

Requiring a non-contact measurement solution and colour map reporting softwareMiroslav Pavlu, Measuring Technician at Lukov Plast explains that to manufacture assemblies and components which will withstand regular day to day use, products are subject to various life cyle and climatic tests. These tests are conducted to assess the performance of the part. Subsequent analysis then takes place to compare states.

Previously, when conducting these tests and QA procedures, touch measurements with a CMM and various manual measuring gauges were used. Particularly the larger plastic parts pose challenges towards touch probe measurement. The difficulty lies in clamping the parts to be measured; deformation due to fixturing and using complex counterparts is to be avoided. A laser scanner offers repeatability and acceleration of inspection in a way that also lowers the cost of ownership: less dedicated fixtures are required as in the case of traditional tactile inspection. This results in a shorter time-to-market.

Czech based company, Lukov Plast, producer of plastic automotive components and sub-assemblies, reports considerably faster measurement cycles and feature measurements following installation of a Nikon Metrology LC15Dx laser scanner.

Case study Laser scanning cuts cycle times by 50%

25News I Volume 13

With the limited repeatability of touch probe measurement, the whole measurement process needed to be improved and refined. Controlling the injection tools allows to steer the process correctly from the start. It was decided that the measurement process needed to be faster, more efficient and more accurate. The possibility of analysing parts with the ‘colour map’ was a major reason for looking to invest in a newer technology.

To find the right product and the right supplier, several meetings were held. An upgrade from Nikon Metrology was clearly the most cost effective solution. With extensive expertise in retrofitting, integrating to 3rd party systems and the best-in-class laser scanning technology the decision was taken to install a LC15Dx laser scanner with Focus point cloud software.

Cycle times decrease by 50%The introduction of the Nikon Metrology LC15Dx laser scanner and Focus software meets, and exceeds the demands of Lukov Plast in many aspects. The colour map is a major benefit in both its simplicity for sharing information with colleagues and the time-to-market for the customers.

“Thanks to the ability to create scanning programs, both for measurement itself and for analysis, including setting up, we can measure very quickly, efficiently and especially comparatively, which makes a big difference for the development of our products. The final protocols with the colour map are also easily readable for other colleagues".

The chosen solution provides greater efficiency in meeting measurement requirements, such as the possibility of aligning on certain selected features of parts, the possibility to align using RPS points or to create the BestFit alignment for the whole surface.

"Measurement has improved significantly, accelerated about 50% and the programming is more efficient, about 40%. Furthermore the fact that the colour map is easy to understand for our colleagues and our customers, this speeds up the measurement evaluation”.

With the introduction of a Nikon Metrology laser scanner an element of uncertainty is removed. For new parts, the creation of part programs is considerably quicker and the technician doesn’t have to deal with fitting a

part, since the technology is contactless. Not

only is the speed a major benefit, but together

with the ease of programming and reporting,

it results in a range of benefits.

Beyond the scope of dutiesLukov Plast reports higher measurement

productivity, higher accuracy and repeatability

as the major benefits of the new system,

as well as new possibilities. Currently the

LC15Dx is used primarily in the Engineering

department. However, with CAD comparison

and the ability to reveal undesired distortions,

the Development department has also made

use of the equipment for testing new products

and prototypes.

An extra plus point was the local service

organisation, Topmes s.r.o. which can perform

full, adequate training pinpointed to the

client's needs. Based in Prague, the company

plays a key role in providing native support,

even beyond the scope of their duty.

All in all, matching the LC15Dx laser scanner

and Nikon Focus software with the existing

CMM machine has been a game changer.

From sharing and reporting data with the

colour map for simplified and straightforward

customer meetings without having a need for

in-depth metrology knowledge, to contactless

scanning, the installation has proven to be

fast, accurate and highly repeatable. Miroslav

concludes, “We are more than satisfied”.

The LC15Dx CMM laser scanner measures the plastic automotive sun visor assembly at Lukov Plast.

Miroslav Pavlu, Measuring Technician at Lukov Plast: "The colour map is easy to understand for our colleagues and our customers, this also speeds up the measurement evaluation”

“ Measurement has improved significantly, accelerated about 50% and the programming is also more efficient, about 40%.”Miroslav Pavlu – Measuring Technician at Lukov Plast.

26

Drilling for oil or gas is an expensive business, whether offshore or on land, so it is essential for E&P (exploration and production) companies to minimise the risk that their planned drilling operations will fail or not meet target yield. Aberdeen-based Premier, COREX, part of the Premier Oilfield Group and a leading global provider of core analytical services to the oil and gas industry, is the preferred supplier of data for risk mitigation to operators worldwide. Customers are to be found worldwide through Europe, North Africa and the Middle East to the USA and Australia.

The firm has been providing these services for more than 30 years but it is only within the last decade that it has augmented its rock core investigations by sending samples for analysis approximately every week to Nikon Metrology's centre of excellence for microfocus computed tomography (micro-CT) in Tring, Hertfordshire. The systems and the X-ray sources that power them are manufactured on site in three factory units, with further areas devoted to service and support. The company also provides subcontract CT scanning services using its own equipment, which doubles as a demonstration facility.

Solids migration analysis beats porosity testingIan Patey, Manager Formation Damage and Stimulation Group at Premier, COREX explained, "Operational fluids are used to assist the drilling and completion of boreholes by providing hydrostatic pressure and preventing formation fluids from entering the well bore, as well as to cool and clean the drill bit and evacuate drill cuttings. We advise on the best drilling fluid to use for a particular job to avoid formation damage and limit corrosion.

"The fluids inevitably interact with the wellbore, changing the structure and porosity of the rock

which can in turn restrict or increase the flow of gas or oil from the reservoir. In the former case, hydrocarbon recovery is compromised.

"One of our jobs, therefore, is to take representative core samples from various depths, particularly at critical intervals in the strata, to identify any alteration in the rock. We look in particular at the addition or removal of solids that could indicate accumulation or strippage from the framework and hence negative or positive changes to flowrate."

One member of staff in the Aberdeen laboratory closely involved with this work

•

Scottish company improves the way it interprets Nikon Metrology's CT scans of rock core samples

Case study Major advance in well bore analysis

27News I Volume 13

is formation damage geologist and project coordinator Leigh Wright. He commented, "Being able to simulate wellbore operations and reservoir conditions accurately, whether to pre-screen a proposed operation or troubleshoot an existing project, requires data from rock samples taken using an array of different equipment for observation, measurement and chemical analysis.

"However, micro-CT scanning is the key technology, as it is central to providing a true picture to our clients. We have found that simple before-and-after permeability measurements on a sample can be a misleading metric to predicting oil or gas flow impairment.

"Much more accurate is being able to look at the deposition or removal of solids such as clay fines to see how they have migrated, which shows the physical alteration. A major advantage of CT is that it can separate materials based on their density characteristics. Three-dimensional change modelling from scan data using our Avizo visualisation and analysis software is an excellent tool for seeing how the rock is actually altering over time."

Rapid subcontract scanningMicro-CT scanning adds value to Premier, COREX's formation damage testing procedures by aiding interpretation and reducing risk to operators. Rock samples flown down from Aberdeen to Tring are typically 25 to 38 mm in diameter, 25 to

50 mm long. A team of Nikon Metrology applications engineers is on call and has at its disposal six of the company's machines to perform subcontract inspection. Turnaround time for Premier, COREX's receipt of results is two days, including flights.

Mr Patey added, "We carried out an internet search at the outset and identified Nikon as likely to be the best provider of contract CT services due to the company's size and the fact that it is a commercial organisation rather than a university or R&D centre. We also liked the reassurance of working with the manufacturer of the equipment. The service we receive is always professional and prompt and the imaging capability of their systems is excellent."

High-resolution micro-CT scanning is non-destructive and can reveal bedding features, fractures, cements and heterogeneities that are smaller than one micron. The images and data sets produced can show grain size and shape, pore size and network, cements and mineralogy and can potentially visualise fluids and saturation.

The resolution of a typical medical CT scanner would be sufficient to show coarse features but not individual grains, pores, micro-

fractures, voids and fine features. Conventional testing techniques such as scanning electron microscopy and thin section are commonly used to understand what has happened within core samples and they provide valuable data. However, they are destructive testing procedures and unable to examine the entire volume of a core sample to show distribution of damage quickly or cost-efficiently, so there is potential to miss the mechanisms involved.

PatentsPremier, COREX has a patent (GB (granted): GB2524810 and US (publication number): US2017108483 to take its rock core analytical services a step forward by using volumetrics to quantify the alteration to the sample over time. Micro-CT scanning will be pivotal to its successful application.

The idea is to segregate the damage mechanisms by simulating them in 3D using the virtual scan model, with the flexibility to anticipate how the rock structure will alter under the influence of a single change, a second change, or both. The technique is being developed to include the ability to overlay combinations of up to seven variables, providing a powerful analytical and predictive tool.

The images and data sets produced can show grain size and shape, pore size and network, cements and mineralogy.

“Micro-CT scanning is the key technology, as it is central to providing a true picture to our clients.” – Ian Patey – Premier, COREX.

“ A major advantage of CT is that it can separate materials based on their density characteristics.”Ian Patey – Manager Formation Damage and Stimulation Group at Premier, COREX.

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NIKON METROLOGY NVGeldenaaksebaan 329B-3001 Leuven, BelgiumTel: +32 16 74 01 00 Fax: +32 16 74 01 03Sales.NM@nikon.com

More offices and resellers at www.nikonmetrology.com

NIKON METROLOGY EUROPE NVTel: +32 16 74 01 01Sales.Europe.NM@nikon.com

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