Custom Metrology

We’ve built an outstanding line of metrology systems for a wide range of industries. At the same time, we understand that some customers have such unique manufacturing processes and user interfaces that only a customized system will be effective. If you need a highly specific solution to suit your manufacturing process, we’ll begin with a standard measurement system, then refine or completely reshape it to meet your precise needs.

Customization options

Our engineers will work directly with you to develop a system that integrates elegantly with your specific environment—from your production line to your user interface. For instance, we can:

  • Customize the scanner and the GUI to complement your online environment.
  • Develop a highly specialized contact lens inspection system.
  • Build a metrology solution tailored to the unique tasks of your R&D efforts.
  • Configure a system to work within any mechanical constraints.
  • Design a user experience through our software toolkit that will complement your current User Interface/UI.
  • Build custom accessories that further enhance the functionality of your system.

Click here to view our Discovery Service data sheet for more information on how Lumetrics can help solve your complex metrology solutions.


Custom probe design, used in-situ, at plastic injection molding facility of one of the largest consumer products companies in the world
Custom probe design, used in-situ, at plastic injection molding facility of one of the largest consumer products companies in the world
Challenge:

A customer approached Lumetrics with a desire to better understand the thickness profile during the molding process of manufacturing a plastic bottle. Due to cycling mechanical machinery within a 24-inch window around the pre-form, a standard probe (with standoff maximum of 2 inches) could not be used while the machine was running.

Solution:

Lumetrics designed a custom probe with a standoff distance of over two feet that could be mounted to allow in-situ wall thickness measurement of molten paracin straw pre-formed plastic bottles just prior to the molding operation. The customer was able to obtain thickness data at discrete areas of the bottle and provide the needed thickness profile to generate their molding simulation. This allowed them to further understand the science behind their molding process and optimize their feed, pressure, and temperature profiles in their molding machine.

Solution Components:

  • OptiGauge MLS
  • 1 – 600mm Custom probe
  • 1 – Custom probe mounts with tip/tilt capability and mounting fixturing
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Custom scanning system for polishing large glass flats
Custom scanning system for polishing large glass flats
Challenge:

A customer came to Lumetrics with a request to design a scanning system that could measure a large three foot diameter glass flat while it was being polished. The customer wanted to be able to quickly and easily move the glass flat among a number of different polishing stations.

Solution:

Lumetrics designed a system that could be moved around various polishing stations in the customer’s factory with a small crane.

Solution Components:

  • OptiGauge MLS
  • Custom X/Y automated scanning system with manual Z probe mount with tip/tilt capability
  • 1 – 50mm probe
  • Custom user interface using OptiGauge Control Center Tool Kit
Learn how we can help you
Custom scanning system for measuring blood bags
Custom scanning system for measuring blood bags
Challenge:

A customer came to Lumetrics with a request to design a scanning system that could measure a number of seams on blood bags during the manufacturing process. There would be four bags attached and the customer wanted measurements at multiple locations including the side seals and seals around the tubes going into the bags.

Solution:

Lumetrics worked with a local robotics house and custom designed a stand-alone station that could accommodate 8 bags and provide automated measurement with only loading and unloading required by the machine operator.

Solution Components:

  • OptiGauge MLS
  • Custom RoboCart stand-alone workstation with 6-axis Fanuc robot and training tools
  • 1 – 25mm HNA probe and robot mount
  • Custom user reports and data capture using OptiGauge Control Center Tool Kit
Learn how we can help you
Multiple Probe installation at specialty films company, measuring coating at both wet and dry locations
Multiple Probe installation at specialty films company, measuring coating at both wet and dry locations
Challenge:

A customer approached Lumetrics with a request to understand and control their specialty film making process by measuring the thickness of the film at multiple locations along the production line. They also needed a custom user interface screen installed for their Korean plant.

Solution:

The customer was applying an adhesive to a base film and wanted to understand the application and the drying process to produce film to tighter tolerances and with less scrap. Lumetrics reviewed the production line and process with the customer and decided on using our OptiGauge MLS with 8 fixed probes vs. a scanning system. Fixed probes gave them the simplicity they were looking for and also gave them flexibility if they needed to adjust the 8 probes in the installation. With the custom designed user interface screen their operators were able to easily control their process and improve the quality of their film.

Solution Components:

  • OptiGauge MLS
  • 8 port Optical switch
  • 8 – 50mm probes
  • 8 – Custom probe mounts with tip/tilt capability and mounting fixturing
  • Custom user interface using OptiGauge Control Center Tool Kit
Learn how we can help you
Multi-probe fixture for online tubing measurement
Multi-probe fixture for online tubing measurement
Challenge:

Multiple customers have approached Lumetrics with requests for measurement of Wall Thickness, OD, and ID of tubing from a single measurement device. Current practices generally include a laser gauge for OD, an ultrasonic gauge for wall and ID measurements. This requires combining data, at two different locations, from the two gauges. Additionally, ultrasonic systems cannot be used for hydrophilic materials, such as silicone tubing.

Solution:

Customers have used the two system approach for years to measure all the variables of tubing. When making hydrophilic tubing they have relied on OD laser gauges and manual pin gauges and other off-line devices for ID and wall thickness. Because an OptiGauge® can connect multiple probes to a single unit, we designed a 4 probe fixture to precisely position the probes around the tubing while stabilizing the tube. The system allows adjustment for multiple size tubes and provides Wall Thickness, ID, and OD measurements along with ovality and concentricity. The flexible design allows for easy transition for precise measurements of multiple sized tubing.

Solution Components:

  • OptiGauge MLS
  • Online tubing fixture with base stand
  • 8 port Optical switch
  • 4 – 25mm HNA probes
Learn how we can help you
Specialty scanner for silicon wafer measurement
Specialty scanner for silicon wafer measurement
Challenge:

Customer had a need to measure voids in bonded silicon wafers. Detecting voids in bonded wafer pairs is critical for ensuring robust bonding processes and managing yield. Previous methods of measurement including IRISCN, IR transmission imaging, and scanning acoustic microscopy could not provide the accuracy, repeatability or speed that the OptiGauge provides.

Solution:

Lumetrics partnered with a silicon wafer equipment manufacturer to design and build the X/Y scanning system and specialized software to enable correct measurements. Demonstrations showed the OptiGauge had superior performance to existing methods of measurement. Development partner used Lumetrics’ specialized software interface to integrate the OptiGauge controls into the customer’s specialty software.

Solution Components:

  • OptiGauge MLS
  • 50mm probe
  • Custom X/Y automated scanning system with manual Z probe mount with tip/tilt capability
  • Custom user interface using OptiGauge Control Center Tool Kit
Learn how we can help you
High Precision specialty scanner for glass plates
High Precision specialty scanner for glass plates
Challenge:

Customer had a need for specialty scanner with high vibration resistance, extreme accuracy, and high repeatability. A surface profile was required but the customer did not want to provide an expensive reference surface for every different sample to be tested.

Solution:

Lumetrics partnered with ASE Optics to design a specialty scanner with a built in reference piece in the table. The table provided solid measurements with no vibration. The table used a specially designed X/Y scanning system with probe. The reference piece can be easily positioned and allows easy access for any test sample. Specialty software was written using OptiGauge Control Center Tool Kit.

Solution Components:

  • OptiGauge MLS
  • Specially designed probe
  • Custom X/Y automated scanning system with manual Z probe mount with tip/tilt capability
  • Custom user interface using OptiGauge Control Center Tool Kit
Learn how we can help you
Multiple Probe installation, with scanners, at a major consumer goods company, measuring coating of multi-layer film for food packaging
Multiple Probe installation, with scanners, at a major consumer goods company, measuring coating of multi-layer film for food packaging
Challenge:

A major food packager asked Lumetrics to help reduce their costs for packaging of a meat product. Their packaging was a three layer film with the inner barrier layer being crucial to maintaining freshness. Prior to Lumetrics, because their measurement method was inaccurate, they would over engineer the middle layer by 20% or more. This middle layer was very expensive and the customer wanted to reduce material in that layer. By accurately measuring the film real-time Lumetrics gave the customer a tool to reduce the inner layer without compromising the meat product’s quality.

Solution:

Lumetrics designed a scanning system that measured both a top and bottom film that formed the package. A scanning system gave the customer full cross web construction and allowed them to tighten their production specs, savings millions in the plants that they installed the systems. Each OptiGauge controller multiple production lines through the use of an optical switch and multiple probes. Specialized fixturing and scanners were provided because of the caustic wash-down materials used in the food production process. Specialized software was also provided for display to allow the operator to tightly control the production process.

Solution Components:

  • OptiGauge MLS
  • 8 port Optical switch
  • 8 – 50mm probes
  • 8 - Custom stainless steel probe mounts with tip/tilt capability and mounting fixturing
  • Multiple single axis scanning systems
  • Custom user interface using OptiGauge Control Center Tool Kit
Learn how we can help you
Single Probe installation on 360° scanning system for blown film
Single Probe installation on 360° scanning system for blown film
Challenge:

A manufacturer of film used for medical products was producing blown film and needed a method to measure, real-time, the thickness of the film. Issues had occurred that required continuous measurement of each roll of film, with reports that could be given to the end user of the film. The manufacturer had only been providing manual measurements of the very end of the roll.

Solution:

Lumetrics designed a scanning system that rotated a probe 360° around the film as it was being extruded. Specialized software captured the data and displayed it real-time in a customized screen. Data was retained and then downloaded onto roll reports. A scanner and specialized fixturing were provided. To allow the operator to tightly control the production process, specialized software was written for online display using the OptiGauge Control Center Tool Kit.


Solution Components:

  • OptiGauge MLS
  • 1 – 50mm probe
  • 1 – Rotational scanning system including mounting brackets, stainless steel components, tip/tilt probe holder, fiber optic track, and guards
  • Custom user interface using OptiGauge Control Center Tool Kit
Learn how we can help you