In high-volume aerospace manufacturing, the Coordinate Measuring Machine (CMM) is often the primary bottleneck. This case study details how transitioning from discrete point probing to dynamic VAST active scanning unlocked massive throughput gains for a Tier-1 engine supplier.
The Challenge: Blisk Airfoil Inspection
The client was manufacturing a titanium Integrally Bladed Rotor (Blisk) consisting of 42 individual blades. To satisfy the strict GD&T calling out complex profile tolerances on both the pressure and suction sides of the airfoil, the legacy inspection program was acquiring over 3,000 discrete touch points.
Using a standard touch-trigger probe on a gantry CMM, the total cycle time per part was exceeding 4.5 hours. With a production ramp-up imminent, this inspection bottleneck was threatening the entire delivery schedule.
The Solution: ZEISS VAST Navigator Technology
Service Metrology was contracted to optimize the process. We migrated the inspection routine to a ZEISS PRISMO Fortis equipped with a VAST XT gold active scanning sensor, programmed via CALYPSO software.
"Active scanning doesn't just collect data faster; it constantly measures its own deflection, dynamically adjusting the measuring force in real-time to maintain constant contact with complex geometries."
The optimizations included:
- Dynamic Path Generation: Modifying the CALYPSO curve features to utilize the "Navigator" technology, which automatically calculates the optimal scanning speed based on the curvature of the blisk, slowing down for sharp leading edges and accelerating across flat expanses.
- Filtering Algorithms: Implementing a robust Gaussian filter (UPR 50) to mathematically separate the intended geometry from the surface roughness of the titanium forging, something impossible with discrete points.
- Rotary Table Integration: Synchronizing a 4th-axis ZEISS rotary table allowed us to inspect all 42 blades using a single stylus qualification, entirely eliminating the hundreds of index changes required by the articulating head in the legacy program.
The Result: 40% Reduction in Cycle Time
The new CALYPSO program successfully reduced the inspection time from 4.5 hours to 2 hours and 40 minutes—a 40% reduction. Furthermore, because VAST scanning acquires thousands of points per second, the data density increased dramatically. We were providing the client with significantly higher confidence in their profile form measurements, in nearly half the time.