Verified quality: 1zu1 relies on state-of-the-art computed tomography for quality assurance

The Vorarlberg high-tech company 1zu1 invests around 500,000 euros in a modern computed tomography scanner for the industrial measurement of injection-molded and 3D-printed components. (Photo: Darko Todorovic)

Using computed tomography, the entire volume of the components can be examined for the first time in 1:1 scale, with the highest resolution and accuracies of 5 micrometers. (Photo: Darko Todorovic)

1zu1 takes quality assurance to a new level with state-of-the-art computed tomography measurement. (Photo: Darko Todorovic)

In industrial computed tomography, a three-dimensional model is created from a multitude of projections after rendering. (Image: 1to1)

The evaluation of the CT scan at 1:1 is performed using software and color comparison. Red indicates a deviation of +0.2 millimeters and blue indicates -0.2 millimeters. (Image: 1:1)

1to1, a specialist for prototypes and small series from Vorarlberg, invests around 500,000 euros in a state-of-the-art computed tomography scanner for 3D measurement. The system of the latest generation allows for the first time a complete, contactless and non-destructive digital recording of all internal and external structures of the components. Through high-resolution measurement with accuracies up to 5 micrometers, 1to1 can guarantee its customers absolute quality proof in injection molding and in the precise selective laser sintering process FDR.

"We are increasingly focusing on delicate, detailed components in small and medium-sized series up to 50,000 pieces. This is done through injection molding and 3D printing with the high-resolution selective laser sintering technology Fine Detail Resolution (FDR)," explains 1to1 Managing Director Wolfgang Humml. For minimal component sizes of 5 millimeters and complex, internal geometries such as channels or air chambers, quality is the decisive factor. "We can produce very fine, highly precise structures in series. Through the digital replica of the component, we now also provide our customers with the absolute quality proof," explains Humml. With the €500,000 investment in the computed tomography system, 1to1 can for the first time examine the entire volume of objects – with a resolution of 3000 x 2500 pixels, almost in 4K quality.

Pioneering work for industrial measurement technology with computed tomography

The choice of 1to1 fell on the newly available model exaCT L 150 from the German measurement technology company Wenzel. The system, about two meters high and two meters wide, is precisely tailored to the needs of 1to1 with a 150-kilovolt tube voltage, detector resolution, and a measurement volume of 300 millimeters in height and 150 millimeters in diameter. As one of the first worldwide users, 1to1 acts as an important reference customer for Wenzel. "The market has not yet seen such performance capability. We are proud to be able to fully utilize the potential of the system," says Humml.

Fast, precise, and comprehensive inspection

The new technology allows insights into the interior of components that were previously impossible. "The computed tomography detects everything, every unevenness, every speck of dust. The data are more than twice as accurate as optical measurement," reveals 1to1 measurement expert Marco Hermann. With an accuracy of five thousandths of a millimeter (0.005 mm = 5 μm), volume measurement approaches tactile measurement.

Depending on the component, the measurement process takes between ten and twenty minutes. The evaluation is carried out via software and color comparison. From 2022, the last manufactured parts of all injection molding series will be inspected and analyzed at 1to1 using computed tomography. "Our customers receive a detailed measurement report for each batch. This takes our quality control to a new level," emphasizes Managing Director Humml.

Precise imaging through X-ray radiation

In industrial computed tomography, the component placed on a custom Styrofoam fixture is scanned by an X-ray tube and projected onto a detector. By rotating in minimal increments, all views are captured. From numerous projections, a three-dimensional model is generated after rendering. "Unlike optical 3D measurement, all data are recorded – including internal structures. This allows us to obtain a complete image of the object for the first time," explains Marco Hermann.

Even transparent components can now be measured easily. In optical measurement, a very thin lime plaster layer had to be applied via spray. "We save the pre- and post-processing as well as measurement distortions and blind spots on the measurement map," says Hermann. Another advantage is the free placement of components within the measurement area. The closer to the tube, the higher the resolution. Conversely, the system allows multi-measurements of up to 20 parts at maximum distance. "With the exaCT L 150, we can inspect complex parts at miniature scale and guarantee our high quality standards," says Wolfgang Humml.