Tech Focus: Advancing Inline Quality Control with High-Precision 3D Metrology

Robotics & Automation INSIDER

The robot vision system detects defects and imperfections in parts in real time. (Image: senswork)

A new state-of-the-art robot-assisted 3D inspection and metrology system designed for real-time quality control in manufacturing, is being showcased by senswork Inc. (Johnson City, TN) at the Automate show alongside Photoneo, now part of Zebra Technologies. The fully automated inspection cell leverages collaborative robotics and advanced 3D vision to detect defects and perform precise 3D measurements directly on the production line.

Automate visitors will experience how senswork’s robot vision system, powered by Photoneo’s 3D sensing technology, enables:

Real-time defect detection – Identifies imperfections, dents, and deformations with high precision.
GD&T-compliant 3D metrology – Performs accurate inline measurements for tight tolerance manufacturing.
Seamless integration into production – Supports continuous, automated quality control.

Traditional 2D inspection systems often struggle with variable surface textures and materials. In contrast, senswork’s 3D inspection technology provides material-independent accuracy — works on reflective, textured, or multi-colored surfaces; consistent defect detection — no reliance on contrast-based image processing; as well as reliable pass/fail decisions — eliminates false positives caused by lighting variations.

The technology enables companies to perform 3D measurements directly at the production line and simultaneously detect surface defects. (Image: senswork)

“The combination of state-of-the-art 3D machine vision and collaborative robotics opens up new possibilities in industrial quality inspection," said Roman Rieger, CEO of senswork. “Our technology enables companies to perform 3D measurements directly at the production line and simultaneously detect surface defects. Thanks to their ability to detect defects regardless of texture or material, they offer a particularly robust and reliable solution for automated quality control.”

The system offers a scan volume of approx. 900 × 600 × 400 mm (combination of the scanning area of the PhoXi 3D Scanner-M and the travel range of the UR5e robot). It enables flexible capture of complex geometries. By precisely positioning and tilting the scanner (up to 90° via the robot), undercuts can be minimized and hidden features reliably captured. Another advantage is its individually adaptable scanning process — the number and position of scans can be tailored precisely to the specific inspection part. The robot extends the working area without the need for additional scanners. The entire robotic table is mobile and can be positioned flexibly within the workspace.

“By combining our 3D Vision with senswork’s expertise in robotics, we are tackling some of the toughest challenges in inspection. This collaboration enables manufacturers to achieve unparalleled accuracy, detect defects in real time, and streamline quality control processes with greater efficiency than ever before” said Frentišek Takáč, Global Strategic Partnerships Manager - Robotic Vision at Photoneo. Automate Booth #641

For more information, visit www.senswork.us .