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Optigo Applications Gallery
Optigo is used to accelerate and improve dozens of common Automotive & Aerospace industry applications during product development, engineering & ramp-up. Below are examples of Optigo supported customer applications.
Digitize Design and Styling Models to 3D

Application Highlights:
- Supports design and development of new product models 
- Captures entire clay model surfaces including fine geometries  
- Transforms measurements into commonly supported high quality polygon meshes (STL)
- Reverse engineer surfaces to capture design intent into CAD models


Customer Reported Benefits:
- Measuring clay models as is – no powder needed
- High accuracy 3D reconstruction reducing manual data processing  
- Producing geometric adaptive point clouds and STL models in smaller file sizes for easy handling




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Prototype Part Development & Quality Assurance

Application Highlights:
- Supports initial activity of producing small batch of prototype parts at either supplier facility or OEMs new model center
- Measures surface of soft strike dies
- Measures part panels for surface and feature deviation before and after laser trimming

Customer Reported Benefits:
- Eliminate the need for costly checking fixtures
- Reduce measurement time to minimum
- Conduct the measurement directly on the production floor
- Reduce amount of scrap and required rework on parts


Prototype Body Assembly Development
Application Highlights:

- Measures partial or full prototype car bodies to evaluate the expected assembly process and results
- Analyze interest areas on the body which affect subsequent assembly operations
- Measures car body assemblies on their fixtures
- Analyzes mating / matching interfaces

Customer Reported Benefits:

- Get real-time results to support iterative quality improvements
- Guide the manual assembly tools and fixtures adjustment
- Help solve engineering problems faster
- Quickly adjust datums for improving assembly


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Die Casting Measurement & Cutter Path Optimization
Application Highlights:

- Performs complete surface measurement of die casting and compare results to design for initial dimensional evaluation
- Automatically generates an STL output to the casting for update the CAM (Computer Aided Machining) process

Customer Reported Benefits:

- Reduce machining time by optimizing cutter path based on actual die casting dimensions
- Identify shallow / higher areas compared to CAD to avoid missing the material and machining air as well as reducing the chances of crashing the tool due to an unexpected bump
- Reduces machining “air time” to minimum and allow operation without constant supervision


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Die Machining Validation
Application Highlights:

- Performs complete surface and feature measurement of the machined die after machining
- Use CoreView Pro to compare measurement results to Die CAD and identify deviations.

Customer Reported Benefits:

- Quickly verify that the produced Die sets meet engineering specifications
- Guide necessary rework or fine machining to the exct required areas


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Virtual Die Matching & Clearance Analysis
Application Highlights:

- Perform complete dimensional measurement of the lower and upper machined dies to construct a virtual 3D model
- Use Optigo’s embedded software or Off Line Measurement to virtually assemble the die set and check for potential collision or gaps between the dies
- Use cross section and measurement features to resolve die matching issues

Customer Reported Benefits:

- Reduce chances of crashing the dies during initial tryout of die sets
- Pinpoint cause for die matching problems and provide focused guidance for rework operations


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Operational Panel Measurement
Application Highlights:

- Measures operational panels throughout the press line tryout process
- Compares measurements to operational panel designs
- Uses CoreView Pro to compare measurements to analyze cause and effect of the different processes on the dimensional quality
- Analyzes the spring back effects using surface color map, edge measurements and cross sections

Customer Reported Benefits:

- Resolve dimensional part forming problems by tracing the problem to its origin die
- Easily translate measured operational panel deviations and spring back to required die changes


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Subassembly Tryout & Functional Build
Application Highlights:

- Support Event based Functional Build to verify from early stages that produced components do not contain problems known to affect subsequent assembly operations
- Analyzes both the actual dimensional measurements of the components and their relationship to mating components during die source & home-line tryouts

Customer Reported Benefits:

- Focus die rework and changes on critical dimensions and save unnecessary operations and delays
- Support die “buy-off” decisions
- Identify die / part changes that can improve the overall manufacturability or appearance of the final body


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Die Tryout & “Buyoff” at Die Source
Application Highlights:

- Supports the die tryout process and reach a good part - without defects and that conforms dimensionally to certain extent.
- Measures the die, operational panels and produced parts for correcting various issues such as wrinkles, splits, spring back and pull back, Burrs, Hem quality and so on.
- Analyzes dimensional accuracy and stability

Customer Reported Benefits:

- Eliminate the need for costly checking fixtures
- Use an agreed format and tool for evaluating dimensional performance of stamping dies
- Reduce number of quality iterations
- Reduce cost of quality for die builders


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Die Archiving
Application Highlights:

- Captures the as built condition of produced dies before leaving the die shop for future use
- Stores a comprehensive 3D dimensional representation which could be turned into an engineering grade STL

Customer Reported Benefits:

- Records required spring back compensation on die for next die program design and engineering
- Use the full dimensional representation of the die to accelerate die duplication and maintenance processes


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Die Duplication, Copy to Exact & LH - RH Transform
Application Highlights:

- Replicates existing and productive die set to scale up production or localize vehicle program production
- Measures entire die parts – surfaces and features and automatically generates a high quality 3D representation used as input for generating a die machining program

Customer Reported Benefits:

- Accelerate die build and tryout process by using actual and proven die dimensions
- Finalize dies for Right Hand parts and transform them to Left Hand dies
- Flexibility in measuring the productive die at its home-line with no disturbance to production and easily communicating results to the die shop


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Die Maintenance & Repair
Application Highlights:

- Measures dies in the stamping plant and compare results to archive measurement to help schedule proactive maintenance operations
- Measure damaged dies, compare to latest version available to help guide repair operations
- Measure broken die parts and virtually assembles them to produce a full 3D model for duplication purposes

Customer Reported Benefits:

- Lower production down times thanks to better proactive maintenance scheduling based on actual measurements
- Faster recovery in cases of die breakage


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Stamping Die Home Line Tune-in
Application Highlights:

- Supports secondary tryout at the home line and gets the die ready for full speed production
- Produces general dimensional diagnostic reports as well as PIST (Percent Inspection Points that Satisfy Tolerance) reports used to evaluate the die’s dimensional quality performance in producing parts
- Analyzes multiple measurements to verify dimensional stability
- Communicates multiple measurements between Tool & Die center or Tier1 supplier and the OEM using the CoreView format
- Supports agreed tolerance adjustments, master part creation and measurement comparison to virtual master part

* This process can be automated using OptiCell

Customer Reported Benefits:

- Accelerated tryout process with fewer measurements for each event
- Easy data submittals for PPAP (Process for Part Approval for Production)
- Improve communication with Assembly using full dimensional representation


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Plastic Injection Mold Development & Tryout

Application Highlights:
- Measures the full surface of molds after CNC and compares results to their CAD to support required rework or tuning.
- Measures tryout parts to identify and correct possible phenomena such as shrinkage, flashings, short shots, faulty geometries and features and part distortions
- Assembly tryout of the plastic parts with car body parts such as fender, hood, Fascia inner etc identifying collisions or possible mismatches


Customer Reported Benefits:
- Detail analysis and problem pinpointing using the comprehensive dimensional information (surface, features, edges, cross sections, etc.)
- Reduce measurement time and modification iteration process to only a few iterations
- Reduce mold tryout time from several weeks to only a few days
- Exhibit better match with car body components




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Fuel Tank Development
Application Highlights:

- Measures blow molded fuel tanks during their development process
- Measures outside tank surfaces and compare results to the CAD or simulated molding model
- Measures and virtually mends tank section with outside surface measurements to analyze the tank’s plastic wall thickness

Customer Reported Benefits:

- Quickly identify and resolve part deformations during initial tryouts
- Provide product designers and engineers with immediate feedback on manufacturability and update simulation models
- Improve fuel tank durability thanks to full wall thickness analysis


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Instrument Panel Matching to Body
Application Highlights:

- Optigo is used to measure the instrument panel’s interfaces to the car body
- Virtually match IP and body after measurements to identify collisions
- Measure flash and gaps between IP assembly and vehicle interior
- Conduct slow build studies to analyze the cause for assembly miss-fits

Customer Reported Benefits:

- No need to predetermine measurement points
- Faster more complete understanding of the root cause for critical issues
- Rapid measurement on the production line by regular line operators
- Supplier products can be easily verified before shipment to avoid penalties for miss-fits
- Helps improve Supplier – OEM relations and trust


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Assembly Root Cause Analysis & Launch Support

Application Highlights:
- Measures parts and subassemblies directly on the assembly lines and on their fixtures
- Utilizes the Airtex accessory for best access to measured objects
- Analyzes root cause for complex assembly problems using slow build methodology that measures assembly after each operation
- Uses Optigo measurement & CoreView Pro software for virtual and digital analysis, cross section deviation analysis, comparison between multiple measurement, etc.


Customer Reported Benefits:
- Accessibility to most confined assembly line areas
- Ability to operate and measure in real assembly line conditions allows real-time decision making
- Quick & comprehensive measurement results and analysis tools to identify the cause of a problem and suggest a possible corrective action.


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Capture 3D Parts & Reverse Engineer for Production
Application Highlights:

- Accurately measures Automotive or Aerospace part shapes, edges, surface geometries and features to produce a detailed 3D representation
- Automatically generates an engineering grade output supported by most CAD platforms for copy to exact or for product face lift purposes

Customer Reported Benefits:

- Speedy process including measurement and accurate 3D model generation
- Highly accurate feature construction into the 3D model based on Optigo’s feature measurement technology
- Faster turnaround from article measurement to production


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Motorcycle Frame Assembly Tuning

Application Highlights:
- Optigo is used to measure the frame parts before assembly and compare to the design
- The assembled frame is measured to confirm assembly process stability and meeting required tolerances
- In case of fluctuating dimensions Optigo is used for slow build studies in the assembly stations to trace cause & correct the problem 
- Measuring frame surfaces and features for root cause analysis of various assembly problems


Customer Reported Benefits:
- Easily measure motorcycle frame subassemblies on the assembly line fixtures
-Getting full dimensional feedback after each operation to support required adjustments to the process or tools
-Accelerated resolution of frame assembly / fitting problems
-Equalizing "identical" stations to produce similar dimensional results


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Space Shuttle Maintenance
Application Highlights:

- Supports the demanding process of measuring, custom manufacturing and fitting of Space shuttle protection tiles
- Measures and digitizes the cavities generated from the missing tiles
- Measures tiles after forming to verify dimensions and guide cutting operations
- Measures produced tiles and virtually analyzes fit into their specific cavities

Customer Reported Benefits:

- Drastically reduce the time involved to replace a tile on the shuttle
- Improve the quality & fit and finish of replacement thermal protection tiles
- Flexible handheld operation in demanding maintenance floor environment while meeting Class1 Div2 requirements


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Additional Optigo Applications - Please Contact Us
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Interested in more information about Optigo and how it can be used in dozens of applications?

We would also be delighted to hear how you are using your Optigo and perhaps add your application to this gallery.

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