Metrology Fixture Design
Verus has been the leader in metrology and the design of fixtures for over a decade. Our diverse range of modular fixtures, the result of years of perfecting our metrology fixture design capabilities, provides measurement solutions for a variety of inspection platforms in addition to product components of almost any shape and size. Therefore, whether you are inspecting parts for medical devices or FMCG, our bespoke CMM and vision system fixtures will not only offer a complete solution to your metrology fixturing requirements but will also help to improve your overall inspection process.
For example, we know that medical devices cannot afford to fail. Additionally, we know how important it is in the medical device industry to have a streamlined metrology inspection process in place. Above all else, this will ensure each component performs and functions to the highest of standards. However, streamlining internal inspection processes goes beyond the metrology platforms used. Equally important is having a metrology inspection lab that is equipped with the best measurement tools, right down to the component holding devices. This is vital to ensure you have a streamlined, precision-led metrology inspection system in place.
Hence, we believe bespoke fixturing is the answer to achieving optimized in-house metrology inspection. The solution to any measurement challenge, a cleverly designed metrology fixture will reduce operator interaction, therefore removing operator variance. Consequently, this removes the risk of interrupting measurement results and guarantees measurement consistency during inspection. Furthermore, our CMM fixtures will increase throughput while improving the reproducibility and accuracy of your CMM. Using innovative advancements, our metrology inspection fixtures allow for the maximum number of measurements to be taken with the minimum number of setups. In most cases, we develop inspection fixtures that allow all dimensions to be taken during a single setup.
We believe in having a creative and innovative solution to client’s measurement challenges yet maintaining a robust and simple bespoke metrology fixture design. As a result, this approach has led to over 150 MedTech leaders partnering with Verus to design and develop custom-made hybrid metrology inspection fixtures to date.
We specialize in the design of quality inspection fixtures for CMM and vision systems as well as hybrid metrology inspection fixtures for use on vision systems and CMM's with touch trigger capability. Furthermore, our metrology inspection fixtures can range from a single station to large repeat multi-station solutions and can incorporate manual or auto-rotational features. Delivering world-class metrology fixtures to global leaders in medical technology and FMCG industries, our fixture design specialists work closely with our clients from product concept to completion. The addition of our vast expertise continues to save our clients large amounts of time and resources that can be best utilized elsewhere.
We strive to offer the best advice to our clients on their components, considering processes and tolerances, while predicting any future potential metrology disputes. Hence, our fixture design journey begins with a metrology workshop with the project leader, our expert design team and the client to develop initial concepts and single station prototypes using an innovative fixture design process. Once our digital concept is proven out and client approval is obtained, the inspection fixture is then ready for manufacture. This process ensures a fast design and development cycle and an optimized final inspection fixture solution.
Verus’ Fixture Design Process
Expert design of fixtures with innovation and automation in mind, we develop initial concepts into high-cavitation, multi-station fixtures. Our design process aims to optimize production processes through innovative, bespoke metrology inspection fixture solutions. Therefore, the metrology fixture design process includes:
- Initial Concepts
- Internal Review
- Design Qualification with Customer
- Approval Stage 1
- Final Design
- Second Design Qualification with Customer (If Requested)
- Release for Manufacture
Designed by metrology engineers for metrology engineers, our bespoke inspection fixtures offer unrivaled durability, wear-resistance and quality while our hard coat anodized finishing provides a smooth and scratch-resistant surface.
From advice on key issues to design, implementation and ongoing support, our expert design team provides a complete turnkey service that delivers innovative metrology solutions to our clients. Our sophisticated metrology fixture design is brought to you by engineering specialists who are ready to help you accelerate your MSA process today.
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Metrology Fixture Manufacture
As toolmakers, Verus Metrology prides itself on the quality, precision, functionality and finish of the metrology inspection fixtures we design and manufacture. From large, complex components to smaller, more intricate parts, our bespoke fixtures improve productivity and increase throughput, saving our clients time and resources.
Since our establishment, we have achieved immense expertise and experience in the manufacturing of our bespoke metrology inspection fixtures. This wide spectrum of proficiency includes the manufacturing of fixtures for single component measurements right through to highly sophisticated, large multi-station metrology fixture solutions. Verus has the capacity and capabilities to provide superior, extremely complex, single-station and multi-station inspection fixtures fit for components of any shape or size.
In-house Manufacturing at Verus
To ensure a fast production turnaround, Verus provides a full in-house manufacturing facility offering highly skilled CNC Machinists, Engineers and Toolmakers. Our world-leading CNC machining teams produce a reliable and repeatable process, resulting in the highest quality of completed metrology fixtures. We develop close working relationships with our clients based on an innovative and mutually respected process of continual improvement.
The manufacture and assembly of our first-class metrology fixtures at each of our facilities enables Verus to service clients worldwide. Our manufacturing facilities, machines and services are tailored to respond to each of our global client’s individual metrology requirements.
Verus’ Fixture Manufacture Process
Adding extra value to client’s measurement activities, our metrology fixtures are second to none in the market. Our in-house manufacturing process results in the highest quality of manufactured precision measuring equipment and metrology fixture solutions. Once our expert manufacturers receive the required book of drawings to match the CAD model, our fixture manufacturing process involves:
- Order Any Required Material
- Mill + Turn the parts from Aluminium, Acetal, Peek, Stainless Steel and Tool Steel
- Fixture Functioning Approval
- Fixture Anodising and Hardening
- Laser Etched of Fixture (If Required)
- Final Assembly
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Metrology Fixture Qualification
We strongly believe in delivering a metrology inspection fixture that will perform and function to the highest of standards. To support this, we perform Gage R&R on all the metrology inspection fixtures we provide. Why do we do this? Well, we know that our clients continue to strive towards improved product and process quality. With our fixture qualification services, clients can be confident that their fixtures are installed and operating according to manufacturing specifications.
One way of doing so is by reducing measurement variation in quality assurance (QA) testing. An effective tool for evaluating measurement variation is Gage Repeatability & Reproducibility (Gage R&R or GR&R). Gage R&R is the process of assessing metrology equipment and processes to ensure measurement systems deliver accurate, repeatable and stable measurement results each time. Hence, understanding Gage R&R is important, as it allows us to predict the probability of measurement error and to identify the source of the variation such as the operator or equipment used.
Gage R&R Explained:
Gage R&R is a statistical tool that measures the amount of variation in the measurement system arising from the measurement device and the operators taking the measurement. A GR&R study allows us to investigate two things:
- Repeatability - How much variability in the measurement system is caused by the measurement device.
- Reproducibility - How much variability in the measurement system is caused by the difference between operators.
When measuring the product of any process, there are two sources of variation: the variation of the process itself and the variation of the measurement system. The purpose of conducting Gage R&R is to be able to distinguish the former from the latter and to reduce the measurement system variation if it is excessive.
However, Gage R&R is not only used for gages but also used for instruments, people, parts and even for the specifications and methods used. It is a combination of all these things and more to quantify precision measurement processes. In short, Gage R&R can quantify the robustness of an entire dimensional measurement system, using accurate and precise data to have the greatest impact on product quality.
Gage R&R: Bespoke Metrology Fixtures
Gage R&R can account for part variability, operator variability and gage variability to ensure your measurement equipment is in good working order. Failure to account for these variables can result in the measurement equipment such as your holding device (metrology fixture or checking fixture) failing or a bad test gage passing. To add, measurement equipment cannot produce reliable data without understanding, quantifying and diligently minimizing measurement uncertainty. This is where expert Gage R&R comes into play.
At Verus, we want to ensure your bespoke metrology fixtures perform to the highest of standards as well as guaranteeing quality and longevity. Hence, Gage R&R is a critical element in the development of our bespoke metrology fixtures.
Verus’ Fixture Qualification Process
Before we deliver a fixture to you, our experts will perform a Gage R&R to ensure the fixture is working correctly. To safeguard the validity of our numbers, we use traditional Gage R&R studies, establish uncertainty budgets for the metrology fixture and perform uncertainty analysis for each measured feature.
In every Gage R&R study, we want you to become aware of how well you can measure your parts utilizing our bespoke metrology fixtures. Completing a successful GR&R depends on several interrelated variables including:
- Measurement Equipment
- Test Methods
The Gage R&R studies carried out by Verus on our metrology fixtures aim for a GR&R variation of less than 10% of the tolerance range. Once the Gage R&R has been completed, the results are loaded into our statistical software package and the metrology fixture is released for delivery.
CMM/Vision System Programming
Along with the Gage R&R report, our expert metrology engineers can create, verify and install bespoke metrology fixture programs on multiple CMM and vision systems. The variety of machine types we work with, along with our capacity enables us to offer individually tailored fixture programs designed to meet each client requirement.
If requested by the client, onsite support can be provided also by one of our expert engineers for fixture installation and qualification.
Where to go from here? Every measurement challenge is unique. Therefore, the easiest thing for you to do is to request a call back from the experts in turnkey metrology solutions. We work with clients to tailor a measurement solution that answers your Measurement System Analysis (MSA) questions.
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