First-article inspection as the foundation for stable mass-production processes
For newly manufactured or modified sheet metal components, it is essential to reliably assess whether their geometry and inspection features meet the requirements specified in the drawing, CAD model, and specifications.
Especially after forming, stamping, or bending processes, springback, material stresses, and tool wear can lead to geometric deviations. A comprehensive assessment of the part geometry therefore provides a reliable basis for approval, process optimization, and the start of series production.
Your Benefits with PROTOS-3D
initial sample inspection with years of experience in the 3D metrology
Sheet metal parts are sensitive to clamping force, their own weight, and springback. Thanks to our many years of experience, we know what really matters when it comes to reliable initial sample inspection .
Years of experience with sheet metal components
Practical knowledge gained from numerous measurement tasks on body, structural, and formed parts.
Expertise in warpage and component mounting
We take into account how stress, springback, and mounting affect the measurement results.
Flexible Solutions with " PRAFS " and "Virtual Clamping"
Proprietary mounting concepts and virtual clamping methods enable a realistic and reproducible evaluation.
From the measurement plan to the finished EMPB
Inspection criteria, target-actual comparisons, and tolerance evaluations are documented in a structured and traceable manner.
Why Sheet Metal Components Pose Special Challenges for Testing
Sheet metal components are sensitive to manufacturing and mounting conditions. Thin-walled or large-surface-area components, in particular, can change their geometry simply due to internal stresses or external forces.
Typical challenges include:
- Springback After Forming
- Deformation Caused by Material Stresses
- Variations in Bending Angles
- Complex hole patterns and functional dimensions
- thin-walled and geometrically unstable regions
- Changes Due to Tool Wear
Point-by-point measurement methods provide very precise results for individual inspection characteristics. In the case of large-area geometric deviations, optical 3D metrology method also offers the advantage of including virtually the entire relevant component surface in the evaluation. This makes it easier to assess local anomalies and overarching geometric relationships together.
The component mounting is part of the measurement strategy
Reproducible positioning – avoid unnecessary stress
Before the measurement, the component is defined and positioned in the measurement system in a reproducible manner. Especially for thin-walled sheet metal components, it is crucial to use a mounting method that minimizes stress as much as possible, so that the mounting itself does not unnecessarily influence the geometry being evaluated.
In addition to traditional component-specific measuring fixtures, PRAFSPROTOS-3D . The flexibly positionable support points enable the reproducible mounting of different component geometries and can significantly reduce the need for custom mechanical fixtures.
For suitable applications, the geometry—captured as freely as possible—can also serve as the basis for ZEISS Virtual Clamping. In this process, a defined installation or clamping condition is subsequently digitally modeled, allowing different conditions to be evaluated based on the same 3D measurement.
Complete 3D scanning instead of individual measurement points
Visual Inspection of First Prototypes of Sheet Metal Components
In the next step, the component is digitized across its entire surface. Depending on the measurement task, PROTOS-3D uses, for example, the ZEISS ATOS 5 and ATOS 5X.
Optical scanning generates a dense three-dimensional data set. This allows both traditional inspection features and large-area geometric deviations to be evaluated based on the same measurement data.
In addition to dimensions, positions, and hole patterns, this method also reveals, for example, warpage, waviness, and geometric anomalies between individual inspection features.
DATA & RESULTS
From Measurement Data to Quality Decisions
The evaluation is based on the defined inspection characteristics and tolerances. Depending on the drawing and inspection plan, the evaluation may include, for example, dimensions, hole patterns, form and location tolerances, contours, radii, bending angles, flatness, and free-form surfaces.
Test Reports & Documented Evaluations
Traceable results for approval, coordination, and quality assurance
Target-Actual Comparisons & Comprehensive Variance Analyses
Quick Overview of Shape and Geometric Deviations
Characteristic Analyses & Tables
Structured evaluation of defined inspection characteristics and tolerances
Data Export & Interfaces
Processed results data for downstream quality and statistical systems
Color-coded deviation displays make springback, warpage, and systematic manufacturing deviations immediately visible, thereby supporting not only component approval but also targeted process optimization.
Document Results in a Traceable Manner
First Article Inspection Report
The relevant test results can be documented in a structured initial sample test report. Depending on customer requirements, this may include, for example:
- Part and Drawing Information
- Defined inspection characteristics and tolerances
- Individual Measurement Values and Tolerance Assessment
- Graphical comparisons of actual versus target figures
- Information on the measurement system and test conditions
- Transparent documentation of results
In addition, measurement and result data can be made available in standardized digital formats for downstream quality, statistical, or documentation systems.
More than just component approval
3D surface measurement does more than simply indicate whether individual inspection features fall within tolerance. It reveals geometric relationships and can thus also provide clues as to the causes of issues in the manufacturing process.
EVALUATE COMPONENTS → UNDERSTAND VARIATIONS → OPTIMIZE THE PROCESS IN A TARGETED MANNER
This way, the measurement results can be used both for the approval of a component and for the optimization of tools, forming processes, and other manufacturing steps.
Typical Applications
Visual first-article inspection is particularly suitable for complex sheet metal and structural components where both individual inspection features and the overall component geometry are relevant.
BODY & STRUCTURAL COMPONENTS · STAMPED PARTS · INTERIOR / EXTERIOR · FUNCTIONAL & MOUNTING PARTS · PROTOTYPES & PRE-SERIES
Frequently Asked Questions About First-Article Inspection of Sheet Metal Components
What is inspected during an initial sample inspection of sheet metal components?
Depending on the drawing and inspection plan, evaluations may include, for example, dimensions, positions, hole patterns, form and position tolerances, contours, radii, bend angles, or free-form surfaces. In addition, the entire relevant surface can be assessed through a comparison of actual and target values.
Why is component mounting so important for thin-walled sheet metal parts?
Even small external forces can affect the geometry of flexible components. Therefore, the component should be mounted in a way that ensures reproducibility and causes as little additional deformation as possible.
What are the benefits of optical 3D metrology?
In addition to individual inspection characteristics, a dense, area-wide dataset is generated. This makes it possible to evaluate even large-scale shape deviations and geometric relationships.
What role can PRAFS play in this?
PRAFS enables a flexible, customizable, and repeatable component mounting system. This reduces the need for component-specific measuring fixtures, particularly when dealing with different variants.
When is virtual clamping used?
For suitable applications, a defined installation or clamping state can then be digitally simulated and evaluated based on the 3D data captured in a free or low-stress state.
From Component Geometry to a Reliable Quality Decision
Optical first-article inspection enables a comprehensive and traceable evaluation of complex sheet metal components. Full-surface 3D scanning, defined component positioning, and measurement plan-based evaluation provide a reliable basis for approval, root cause analysis, and process optimization.
With PRAFS , component mounting can be made even more flexible in suitable applications. Virtual Clamping expands the process by enabling the digital evaluation of defined installation conditions.
Would you like to measure a sheet metal part or prepare for an initial sample inspection?
We can assist you with measurement strategy, component mounting, data analysis, and documentation of results.