An Optical CMM That Calibrates Its Own Lighting

Hexagon launched the next-generation OPTIV S multisensor coordinate measuring machine on 3 September, with tactile accuracy stated as E0, MPEE = (1.6 + L/200) micrometres and machine dynamics roughly 30 per cent higher through increased travel speeds and acceleration. Initial testing showed around a 15 per cent reduction in inspection cycle time. It starts at size 4.4.3 and becomes commercially available on 14 September at IMTS and AMB.

The throughput gains come from two directions. Faster axes shorten the moves between features, and a larger field-of-view vision sensor measures more features per image, which reduces the number of moves in the first place. On a part with many small features, image count often dominates cycle time more than axis speed does.

The more interesting additions are in the software, and they target the part of optical metrology that engineers quietly distrust. A tactile probe touching a surface gives a result that depends on geometry and probe calibration. An optical measurement of the same edge depends on lighting angle, intensity, surface finish, colour and the operator's judgement about focus — which is why two people measuring the same part optically can disagree, and why optical CMMs have a reputation for being repeatable only in the hands of whoever set them up.

Hexagon's answer is to automate those judgements through PC-DMIS. AI edge detection uses AI-assisted camera and lighting calibration to improve edge detection and deliver more consistent results, arriving commercially in PC-DMIS 2026.2. Two further features are slated for 2027: fast auto-focus, claimed up to 50 per cent quicker, and AI illumination, which automatically optimises lighting parameters.

Automatic illumination optimisation is the one that would change day-to-day practice most, because lighting is currently a setup skill rather than a measurement parameter. If the machine chooses it repeatably, the measurement becomes attributable to the part rather than to the person — which is the whole basis on which a gauge study passes or fails.

Manuel Mueller, director of product marketing, framed the driver as pressure to inspect more parts in less time without sacrificing accuracy. Target industries are electronics, medical devices, automotive and precision engineering.