An Overview of 5 Leading Metrology and Inspection Software Languages

September 29, 2022

An Overview of 5 Leading Metrology and Inspection Software Languages

September 29, 2022

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As there is no industry-standard software application or programming language for CMMs and other measurement and inspection equipment, it is beneficial to have an overview of the main options that are available. For quality engineers and metrology technicians, understanding the various metrology and inspection software languages can help in making procurement decisions, as well as giving you a better overview of the market.

You can also get a deeper understanding of the capabilities of various metrology and inspection software languages to help you plan and implement process improvement strategies and initiatives.

Leading Metrology and Inspection Software Languages

Below, we have summarised the leading metrology and inspection software languages currently on the market, with a specific focus on the medical device industry. Those software languages are:

  • Zeiss Calypso
  • ZONE3 by OGP
  • Renishaw MODUS
  • PC-DMIS by Hexagon
  • Mitutoyo MCOSMOS

 

Zeiss Calypso

Zeiss Calypso
Image: Zeiss

Zeiss Calypso is part of the suite of software applications offered by the German manufacturer of metrology and inspection equipment Zeiss. Calypso is compatible with Zeiss metrology and inspection equipment, including its CMMs and sensors. The main highlights of Zeiss Calypso include:

  • Can be used to create measurement plans with no knowledge of coding language, plus it is straightforward to adjust your measurement plans
  • Measurement programs can be optimised remotely
  • CAD import capabilities
  • Sophisticated software that can predict and generate probe movements
  • 3D capabilities
  • Comprehensive and customisable reports
  • Flexible with simple standardisation and intuitive programming
  • Add-on modules available for specific applications

A note from our Zeiss Calypso expert, Michaela Healy:

“Calypso software is fantastic for creating tactile measurement routines, it allows you to fully control every step and ensure each measurement is precise and accurate. Plenty of features like Curve are available to make complicated dimensions much more straightforward.

I’d recommend it for any projects that lean towards probing rather than optics and involves CAD.”

ZONE3 by OGP

OGP ZONE3
Image: OGP UK

ZONE3 is a metrology programming language from UK-based OGP, the metrology manufacturing arm of the Carfulan Group. It is part of a range of software applications designed to work with and optimise OGP’s metrology equipment. ZONE3 has been developed for use with the SmartScope range of multi-sensor metrology systems from OGP. The main highlights of ZONE3 include:

  • Combines functionality that is often found in separate systems into one package
  • 3D programming and animation capabilities
  • Measurement routines are automatically generated by ZONE3’s algorithms
  • It is user-friendly and flexible, so it is compatible with the laser, video, and scanning probes of OGP’s SmartScope systems
  • Native CAD format compatible – just upload and start programming
  • Animation-assisted alignment functionality
  • Comprehensive reporting functionality, including dynamic reporting
  • Minimised training requirement

Renishaw MODUS

Renishaw Modus
Image: Renishaw

British metrology equipment manufacturer Renishaw offers a suite of software applications that work with the equipment in its range. Its coordinate-measuring machines use MODUS. The main highlights of Renishaw MODUS include:

  • CAD-driven programming capabilities plus full integration with a range of CAD applications, including Solidworks
  • Can be programmed offline
  • 5-axis measurement capabilities
  • Built-in algorithms that assist with part alignment and feature measurement
  • Automatic probe path creation with on-screen verification
  • Flexible reporting

PC-DMIS by Hexagon

PC-DMIS by Hexagon
Image: Hexagon MI

Hexagon is a global leader in metrology and inspection solutions. It claims to be the largest developer of software in the metrology industry, and it offers a suite of applications that cover everything from measurement and data analysis to reporting and data management. PC-DMIS is Hexagon’s flagship product. It is a software solution that works with both Hexagon inspection equipment and equipment from other manufacturers through software upgrades or CMM retrofits. The main highlights of PC-DMIS by Hexagon include:

  • Modular, so you can use what you need, and scale as required
  • Reduces training requirements if you use different metrology equipment, as it can work across different measurement systems
  • Compatible with a range of sensor technologies
  • Offline programming functionality allows measurement routines to be created without a physical part
  • Automated creation of collision-free paths
  • Intuitive user interface that is customisable
  • Comprehensive and customisable reporting
  • CAD import capabilities

A note from our PC-DMIS expert, Mark Cawley:

Offline programming available to create measurement routines in advance of parts using 3D CAD models. Built in “collision detection” allows programmer to test measurement routine for potential collisions.

For multi station fixture, program can be created in the first station and “Pattern” into all stations. Reduces the required program time and ensures no differences in the measurement method across all the stations.

Mitutoyo MCOSMOS

Mitutoyo MCOSMOS
Image: Mitutoyo

Mitutoyo is the leading Japanese manufacturer of metrology and measuring equipment. It offers a suite of software applications, including MCOSMOS. It is a modular system that can be tailored to requirements with highlights that include:

  • Integration with CAD software
  • User-friendly interface
  • Excellent data handling capabilities, especially in applications with multi-station fixtures and various coordinate systems
  • 3D modelling capabilities

A note from our Mitutoyo MCOSMOS expert, Nuala Baker:

“I find MCOSMOS is particularly useful when you have very big fixtures i.e. fixtures with more than 8 stations. It handles a lot of data well with the ability to store lots of different coordinate systems easily.

It is particularly well suited to ‘looping’ making it very easy to go from a program for 1 station to a multi station program.

In my experience, it is a very reliable software and the interface is user friendly.”

Conclusion: Powerful Software Applications, But Make Sure You Get the Right Support

The main metrology and inspection software languages all have modern features and powerful algorithms that automate critical parts of the programming process. They are also designed to be as easy to use as possible.

That said, there is still a learning curve and, more often than not, there is a need for expert support and advice. This particularly applies if you need to inspect and measure a complex medical device with small and/or intricate components.

At Verus Metrology, we have experience and detailed knowledge of all the software languages highlighted in this blog. We also have equipment in our metrology labs from all the software vendors.

This means we can provide the expert support that you need, from deciding on the right solution for your requirements to programming a CMM for the inspection of a new device to troubleshooting problems. Get in touch with us today to discuss your requirements.

Introduction 

As 2024 unfolds, the field of metrology is witnessing transformative changes. At Verus Metrology, we recognize the importance of keeping pace with technological advancements and new trends in the science of measurement. In this rapidly evolving landscape, innovations in metrology are not just about achieving precision; they are about meeting the evolving challenges of industries like medical devices, where accuracy is critical for ensuring safety and quality. This article explores the emerging trends and technological breakthroughs shaping metrology’s future. 

As 2024 unfolds, the field of metrology is witnessing transformative changes. At Verus Metrology, we recognize the importance of keeping pace with technological advancements and new trends in the science of measurement. In this rapidly evolving landscape, innovations in metrology are not just about achieving precision; they are about meeting the evolving challenges of industries like medical devices, where accuracy is critical for ensuring safety and quality. This article explores the emerging trends and technological breakthroughs shaping metrology’s future. 

Metrology Fixture Types – What’s Available, and Which is Best?

9 February 2023

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Fixture type and use cases

Metrology fixturing technologies continue to develop at a rapid pace, offering manufacturers in the medical device industry new and innovative solutions. Those solutions don’t just meet inspection and quality process requirements, but they also deliver efficiency savings and productivity gains. How do you know what metrology fixture types are available and which is best for your application? In this blog, we’ll outline the main options, their underlying technologies, and the use cases they are best suited for. 

However, it is also important to point out that the fixture types described in this blog represent broad categories. Within those categories, there is an infinite number of ways that a fixturing solution can be developed to meet your specific needs, reduce risk, and take advantage of opportunity

While there are metrology fixture types that we can explore, every fixture solution that we develop here at Verus Metrology is completely unique. In other words, fully customised for the product or component being measured, as well as the inspection machine, quality department workflows, production processes, and any other influencing factor. 

Metrology Fixture Types 

There are six main metrology fixture types: 

  • Auto rotational 
  • Manual rotator 
  • Multi-station
  • Proof of Principle (POP) 
  • Vision system 
  • Docking station 

 

Auto-Rotational Fixtures

Isometric view of an auto rotational metrology checking fixture, the automatic part of the fixture is the turning of the rail by a motor. The fixture has white plastic components held in place using brown clips

 

At a fundamental level, the job of a metrology fixture is to hold a product or component securely in place so it can be effectively inspected and measured. However, there are situations where the inspection process requires the part to be presented at different orientations to enable all the relevant measurements to be taken. This requirement for measurement in multiple orientations is increasing as medical device products become more complex and intricate. 

Auto-rotational fixtures enable the inspection of products and components in multiple orientations with minimal operator intervention. An auto-rotational fixture can be a single-station set-up, but they more commonly come in multi-station designs to minimise the time it takes to achieve your required sample rate. 

The most important feature of an auto-rotational fixture is that you can measure multiple components in multiple orientations in a single setup. 

Manual Rotator Fixtures

Manual Rotator Metrology Fixtures by Verus Metrology

Manual rotator fixtures offer similar benefits to auto-rotational fixtures. The obvious main difference is that operators manually rotate components once they are loaded into the fixture. 

Manual rotator fixtures can be multi-station. They are also designed so that all measurements in all orientations can be taken in one set-up. So, while the operator will need to manually control the rotation mechanism, there is no requirement to touch or adjust the components as the fixture holds them securely in place during rotation. 

The benefits of manual rotator fixtures include: 

  • Significantly reduced operator intervention 
  • Improved measurement accuracy 
  • Elimination of errors 
  • Faster and more efficient metrology processes 

Furthermore, we can design your manual rotator fixture so it can be loaded with components away from your CMM. This improves CMM availability as the machine doesn’t have to sit idle while components are being loaded onto the fixture. 

Multi-Station Fixtures 

multi station rotator

According to FDA regulations and ISO 13485, it is essential that you can statistically justify sampling rates in your quality procedures using a risk-based approach. The operational part of this requirement isn’t covered in the guidelines, but it is an important business consideration. How do you efficiently, accurately, and cost-effectively inspect the number of products or components that are required to hit your sampling rate target? 

Multi-station fixtures are a common solution. We can design multi-station fixtures in any configuration. This could be a large cavity multi-station fixture, a fixture to inspect very small and complex medical devices, or solutions for products or components of any size, geometry, or characteristic. 

The benefits of multi-station fixtures include: 

  • Operator intervention is greatly reduced 
  • Fixtures only need to be loaded once before full inspection routines can take place on multiple products at the same time 
  • Reduce human error 
  • Speed up inspection processes while achieving your sampling rate target 
  • Reducing the cost of inspections 

 

Proof of Principle Multi-station Prototype Fixtures 

proof of principle

 

In many product development and process change situations, it is beneficial to have a POP fixture that can be used for verification and validation purposes. The approach we typically take at Verus Metrology is to design a multi-station fixture to deliver on your requirements. 

However, before this multi-station fixture design goes into manufacturing, we design and produce a single-station POP prototype fixture. This POP prototype can be manufactured quickly in our advanced manufacturing facility. We’ll then put it through a gage R&R study to give you confidence in its repeatability and reproducibility, before sending it to you for evaluation and testing. 

POP prototype fixtures offer a range of benefits: 

  • Facilitates design for inspection during the product development process 
  • Minimises delays in process verification 
  • Enhances and speeds up the design transfer process 
  • Reduces time to market in line with regulatory requirements 

 

Vision System Solutions

We also design and manufacture fixturing solutions for vision systems in addition to the fixtures we design for use on CMMs. Fixturing solutions that are optimised for vision systems have a number of specific and differentiating features, including ensuring there is a clean and clear view of the part. 

Vision system solutions can also allow for backlighting where necessary. Furthermore, a single set-up is all that is required for the full inspection routine to take place, with parts securely held with as little force as possible. 

 

Docking Systems 

Docking System Verus Metrolody

Docking systems enhance the efficiency of quality departments that use multiple fixtures and/or have high sampling rates. Docking systems are securely fixed to CMMs to make it quick and easy for technicians to load fixtures that are fully set up with components ready for inspection. Once the inspection routine for a fixture is complete, it can be quickly and easily removed from the docking system ready for the next fixture to be loaded. 

With a custom-designed docking system, you can have confidence that each changeover results in precisely secured fixtures for repeatable and reproduceable inspections. 

Choosing the Right Fixture for Your Requirements

There are many factors to consider when choosing the best type of metrology fixture for your requirements. Your budget is an important consideration, as are your ROI goals, quality processes, quality resources, and future requirements. 

The best approach is to speak to a fixture design expert to explore the options and get an understanding of what is possible. Contact us today to find out more. 

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About Verus Metrology Partners

Verus is committed to the enhancement of our client’s metrology laboratories, machine efficiencies, and inspection processes. Since our beginning, our expert metrology engineering team has partnered with some of the world’s largest MedTech multinationals.

 

We specialize in high quantity, difficult to measure, yet critically important, medical device parts. As well as working in the MedTech, Pharmaceutical and Personal Care industry, we also work with metrology departments in the FMCG and Aerospace industry.