Top-Class CT Measurement Technology

The 1zu1 Prototypes GmbH & Co KG based in Dornbirn, Austria, was founded in 1996 by managing partners Hannes Hämmerle and Wolfgang Humml.

Today, the company is part of the internationally active Prototal Group. It produces prototypes, small series and production parts for customers worldwide across a wide range of industries. In manufacturing, 1zu1 utilizes key 3D printing technologies such as laser sintering and stereolithography. When developing new components, the company continuously pushes the boundaries of what is technically feasible in terms of complexity and precision.

Measurement technology plays a crucial role in inspecting the finest details and verifying tight form and positional tolerances. For eleven years, 1zu1 has relied on optical measurement solutions and generates several hundred measurement reports each year.

“We know the limits of optical measurement technology very well,” explains Managing Director Wolfgang Humml. “As our components become increasingly complex and smaller, it was clear that we needed to take the next innovative step in metrology. Comparisons between 3D measurement results and CAD datasets had to become even more accurate and reliable.”

When searching for a new measurement solution, several criteria were particularly important.

The focus was on achieving accurate measurement results across the entire 3D component — not only in areas accessible to optical measurement technology. Industrial computed tomography offers clear advantages in this respect. Compared to tactile or optical measuring systems, a computer tomograph (CT) enables high-precision measurement of internal structures without destructive testing.

Optical measurement technology reaches its limits, particularly when measuring transparent components or parts with highly reflective, mirror-like surfaces. Such parts cannot be measured reliably without prior treatment using anti-reflective scanning spray. However, applying spray can compromise the required measurement accuracy. Industrial computed tomography eliminates this limitation.

Another key advantage of CT is the speed of scanning and evaluation. Thousands of measurement points can be captured within seconds. Additionally, pallet scanning — measuring multiple components in a single scan — shortens process cycles and significantly increases efficiency.

After an extensive evaluation process, 1zu1 selected the eXact L 150 kV CT system from WENZEL Metrology GmbH in Wiesthal. “Ultimately, the guaranteed measurement uncertainty of ±5 µm, the convincing CT measurements of our five benchmark problem parts, and the impressive surface imaging accuracy without software smoothing were decisive factors,” explains Managing Director Wolfgang Humml. “The measurement results were so compelling that we decided to order the first machine built with this configuration. We are very pleased with the system now in operation. The scan times are impressively fast — during the first three weeks alone, we completed around 120 scans during normal working hours.”

The high efficiency of the CT solution enables faster development cycles, saving both time and costs for end customers.

In addition, WENZEL’s CT solution offers one of the smallest footprints in its class at 150 kV while providing a scan volume of 400 mm in height and 235 mm in diameter. “Achieving the largest possible measurement volume within a compact machine design was another important requirement,” says Humml. Alongside its compact footprint and large scan volume, the exaCT L also simplifies logistics: transport and installation require no structural modifications to doors or corridors, ensuring fast and straightforward setup. With a system weight of just 2,650 kg — best in class — the machine also allows flexible installation options.

The eXact L is the latest development within WENZEL’s extensive eXact series. Based on a global market analysis of industrial computed tomography systems, it received the Frost & Sullivan ‘Global New Product Innovation Award 2020’. “The exaCTL combines powerful X-ray performance with a fast detector, enabling rapid inspection of objects and defects,” says Mariano Kimbara, Senior Industry Analyst at Frost & Sullivan. “WENZEL has taken an important step forward with an intuitive user interface that automates measurement parameters through intelligent software, delivering strong customer benefits.” Three independent travel axes provide high flexibility, enabling fast measurement and inspection cycles.

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Due to its strong commitment to quality, 1zu1 handles a wide range of measurement and inspection tasks for its customers. These include volume analyses, shrinkage and distortion compensation, inspection for inclusions and impurities, geometric verification, assembly analyses (multiscan) and process monitoring through measurement series. Measurement and inspection reports are always prepared in a clear, customer-friendly and easy-to-understand format.

1zu1 utilizes technologies such as 3D printing, plastic vacuum casting, injection molding and mechanical manufacturing. A significant share of the company’s investment is dedicated to additive manufacturing, where 1zu1 is considered among the global leaders. Since 2020, the company has also been a pilot customer and development partner for new 3D printing technologies from EOS, one of the world’s leading providers of industrial additive manufacturing systems.

Industrial computed tomography and additive manufacturing are two relatively young technologies that complement each other perfectly. While additive manufacturing enables entirely new structures and design freedoms, CT ensures reliable quality assurance of these innovative components. Based on CT analysis, correction data can be generated to significantly improve both dimensional accuracy and mechanical stability of 3D-printed parts. The complex geometries typical of additive manufacturing often present major challenges for conventional measurement systems — challenges that can only be addressed through CT-based, non-destructive material analysis combined with precise dimensional inspection.

“We appreciate WENZEL’s expertise, consultative approach and strong ability to listen and fully understand our needs and high requirements,” says Managing Director Wolfgang Humml. “Our direct contact, Bernd Fleckenstein, consistently gave us the confidence that we were working with the right partner.” Humml was also impressed by the system pre-acceptance inspection, supported by Dr. Uwe Hilpert, CT Product Manager at WENZEL, who provided detailed and expert explanations of each individual image point measured by the ultra-fast 7.5-megapixel detector.

“The CT training was conducted on-site at our facility in Dornbirn by Dr. Hilpert. After an intensive week of training and a deep introduction to CT technology, our measurement technicians were fully prepared to operate the system from the very first measurement task. Investments like this are enjoyable because they create real added value for us and our customers,” summarizes Managing Director Humml.

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Final Insights

The exaCT L industrial computed tomography system is a versatile testing and measurement solution designed to optimize both components and manufacturing processes. Its high efficiency delivers significant added value for customers by accelerating development cycles and reducing time and costs.

Internal structures can be analyzed and inspected non-destructively, eliminating the need for component destruction while enabling faster scanning workflows and reduced inspection effort. A single scan provides comprehensive data for metrological evaluations and detailed analyses. Reliable measurement results are documented in a clear, customer-friendly and transparent format.

Beyond performance benefits, CT technology also supports product safety and risk management. Even less complex consumer goods produced in large quantities can fail, leading to costly recalls and reputational damage. By archiving measurement data, manufacturers retain the ability to perform retrospective analyses, enabling rapid root-cause investigation, targeted corrective actions, or evidence-based defense against potential claims.

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