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Custom-Metrology

Custom Metrology

Interferometric + Wavefront Measurement Systems Built to Your Specs

We understand that each customer has unique manufacturing processes that may live outside the capabilities of standard solutions and interfaces. That’s where our custom metrology systems come in.

We begin with a standard measurement system, then refine or completely reshape it to meet your precise needs.

Ready for a custom solution?

Work directly with our engineers to develop a system that is designed around your custom requirements.

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Custom Metrology Systems

Our engineers work directly with you to develop a system that integrates elegantly with your specific environment—from your production line to your user interface. Custom capabilities include:

  • Customize the scanner and the GUI to complement your online environment
  • Develop a highly specialized contact lens inspection system
  • Build a metrology solution tailored to the unique tasks of your R&D efforts
  • Configure a system to work within any mechanical constraints
  • Design a user experience through our software tool kit that will complement your current User Interface/UI
  • Build custom accessories that further enhance the functionality of your system
 
Read the case studies below to learn how our custom metrology solutions have helped customers optimize their manufacturing processes and improve quality.

Case Studies

Explore the custom metrology challenges we have helped customers solve.
Probe for Plastic Injection Molding Read the Case  
A Scanning System to Measure IV Bags Read the Case  
New Scanning System for Polishing Large Glass Flats Read the Case  
Probes Measure Film Coatings in Wet/Dry Conditions Read the Case  
Specialty Scanner for Silicon Wafer Measurement Read the Case  
High-Precision Specialty Scanner for Glass Plates Read the Case  
Multiple Probes and Scanners Measure Multilayer Films for Food Packaging Read the Case  
Single Probe Installation on 360° Scanning System for Blown Film Read the Case  
Ready to make us your custom metrology partner?

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Case Study

Probe for Plastic Injection Molding

 

  • Challenge
  • Solution
  • Components
A customer approached Lumetrics with a desire to better understand the thickness profile during the molding process of manufacturing a plastic bottle. Due to cycling mechanical machinery within a 24-inch window around the pre-form, a standard probe (with standoff maximum of 2 inches) could not be used while the machine was running.
Lumetrics designed a custom probe with a standoff distance of over two feet that could be mounted to allow in-situ wall thickness measurement of molten paracin straw pre-formed plastic bottles just prior to the molding operation. The customer was able to obtain thickness data at discrete areas of the bottle and provide the needed thickness profile to generate their molding simulation. This allowed them to further understand the science behind their molding process and optimize their feed, pressure, and temperature profiles in their molding machine.
  • 1 – 600 mm Custom probe
  • 1 – Custom probe mounts with tip/tilt capability and mounting fixturing
Case Study

A Scanning System to Measure IV Bags

 

  • Challenge
  • Solution
  • Components
A customer came to Lumetrics with a request to design a scanning system that could measure a number of seams on blood bags during the manufacturing process. There would be four bags attached and the customer wanted measurements at multiple locations including the side seals and seals around the tubes going into the bags.
Lumetrics worked with a local robotics house and custom-designed a stand-alone station that could accommodate 8 bags and provide automated measurement with only loading and unloading required by the machine operator.
Case Study

New Scanning System for Polishing Large Glass Flats

 

  • Challenge
  • Solution
  • Components
A customer came to Lumetrics with a request to design a scanning system that could measure a large three-foot diameter glass flat while it was being polished. The customer wanted to be able to quickly and easily move the glass flat among a number of different polishing stations.
Lumetrics designed a system that could be moved around various polishing stations in the customer’s factory with a small crane.
  • Custom X/Y automated scanning system with manual Z probe mount with tip/tilt capability
  • 1 – 50 mm probe
  • Custom user interface using OptiGauge Control Center Tool Kit
Case Study

Probes Measure Film Coatings in Wet/Dry Conditions

 

  • Challenge
  • Solution
  • Components
A customer approached Lumetrics with a request to understand and control their specialty filmmaking process by measuring the thickness of the film at multiple locations along the production line. They also needed a custom user interface screen installed for their Korean plant.
The customer was applying an adhesive to a base film and wanted to understand the application and the drying process to produce the film to tighter tolerances and with less scrap. Lumetrics reviewed the production line and process with the customer and decided on using our OptiGauge MLS with 8 fixed probes vs. a scanning system. Fixed probes gave them the simplicity they were looking for and also gave them flexibility if they needed to adjust the 8 probes in the installation. With the custom-designed user interface screen, their operators were able to easily control their process and improve the quality of their film.
  • 8-port Optical switch
  • 8 – 50 mm probes
  • 8 – Custom probe mounts with tip/tilt capability and mounting fixturing
  • Custom user interface using OptiGauge Control Center Tool Kit
Case Study

Specialty Scanner for Silicon Wafer Measurement

 

  • Challenge
  • Solution
  • Components
The customer had a need to measure voids in bonded silicon wafers. Detecting voids in bonded wafer pairs is critical for ensuring robust bonding processes and managing yield. Previous methods of measurement including IRISCN, IR transmission imaging, and scanning acoustic microscopy could not provide the accuracy, repeatability, or speed that the OptiGauge provides.
Lumetrics partnered with a silicon wafer equipment manufacturer to design and build the X/Y scanning system and specialized software to enable correct measurements. Demonstrations showed the OptiGauge had superior performance to existing methods of measurement. The development partner used Lumetrics’ specialized software interface to integrate the OptiGauge controls into the customer’s specialty software.
  • OptiGauge II
  • 50 mm probe
  • Custom X/Y automated scanning system with manual Z-probe mount with tip/tilt capability
  • Custom user interface using OptiGauge Control Center Tool Kit
Case Study

High-Precision Specialty Scanner for Glass Plates

 

  • Challenge
  • Solution
  • Components

The customer had a need for a specialty scanner with high vibration resistance, extreme accuracy, and high repeatability. A surface profile was required, but the customer did not want to provide an expensive reference surface for every different sample to be tested.

 

Lumetrics partnered with ASE Optics to design a specialty scanner with a built-in reference piece in the table. The table provided solid measurements with no vibration. The table used a specially designed X/Y scanning system with probe. The reference piece can be easily positioned and allows easy access for any test sample. Specialty software was written using OptiGauge Control Center Tool Kit.
  • OptiGauge II
  • Specially designed probe
  • Custom X/Y automated scanning system with manual Z probe mount with tip/tilt capability
  • Custom user interface using OptiGauge Control Center Tool Kit
Case Study

Multiple Probes and Scanners Measure Multilayer Films for Food Packaging

 

  • Challenge
  • Solution
  • Components
A major food packager asked Lumetrics to help reduce their costs for the packaging of a meat product. Their packaging was a three-layer film with the inner barrier layer being crucial to maintaining freshness. Prior to Lumetrics, because their measurement method was inaccurate, they would over-engineer the middle layer by 20% or more. This middle layer was very expensive and the customer wanted to reduce material in that layer. By accurately measuring the film in real-time, Lumetrics gave the customer a tool to reduce the inner layer without compromising the meat product’s quality.
Lumetrics designed a scanning system that measured both a top and bottom film that formed the package. A scanning system gave the customer full cross-web construction and allowed them to tighten their production specs, savings millions in the plants that they installed the systems. Each OptiGauge controller has multiple production lines through the use of an optical switch and multiple probes. Specialized fixturing and scanners were provided because of the caustic wash-down materials used in the food production process. Specialized software was also provided for display to allow the operator to tightly control the production process.
  • OptiGauge II
  • 8-port Optical switch
  • 8 – 50 mm probes
  • 8 - Custom stainless steel probe mounts with tip/tilt capability and mounting fixturing
  • Multiple single-axis scanning systems
  • Custom user interface using OptiGauge Control Center Tool Kit
Case Study

Single Probe Installation on 360° Scanning System for Blown Film

 

  • Challenge
  • Solution
  • Components
A manufacturer of film used for medical products was producing blown film and needed a method to measure, real-time, the thickness of the film. Issues had occurred that required continuous measurement of each roll of film, with reports that could be given to the end-user of the film. The manufacturer had only been providing manual measurements of the very end of the roll.
Lumetrics designed a scanning system that rotated a probe 360° around the film as it was being extruded. Specialized software captured the data and displayed it in real-time on a customized screen. Data was retained and then downloaded onto roll reports. A scanner and specialized fixturing were provided. To allow the operator to tightly control the production process, specialized software was written for online display using the OptiGauge Control Center Tool Kit.
  • OptiGauge II
  • 1 – 50 mm probe
  • 1 – Rotational scanning system including mounting brackets, stainless steel components, tip/tilt probe holder, fiber optic track, and guards
  • Custom user interface using OptiGauge Control Center Tool Kit