Since 45 years, Hadleigh Castings has established a reputation as one of the UK’s leading aluminium foundries. The company’s extensive range of aluminium casting technologies and services includes CAD CAM, Pattern Making, Boxless Sand Moulding, Precision Sand Casting, Gravity Die-Casting CNC Machining, Final Finishing and Product Assembly.
Robin Mills, Hadleigh Castings Business Standards Manager explained. “Having looked at several alternative systems that could further improve our quality function and help to increase the flow of our inspection work, we decided to purchase an Edge ScanArm system. Compared to the other available systems, the ScanArm proved to be the ideal tool for product development, inspection and quality control functions.
“Adopting non-contact measurement techniques has considerably speeded-up our 1st article measuring process and significantly reduced our new products’ time to market. An example of the considerable time advantages that we have gained through the use of our FARO ScanArm is the regular detailed inspection that we undertake on a very complex casting. Previously, the painstaking, very precise inspection routine took us over 30 hours to complete. Now, with the use of our FARO Edge ScanArm, we are able to accomplish the complex task with improved levels of accuracy in less than 4 hours” pointed out the Hadleigh Castings Business Standards Manager.
“Given our ever shorter project lead-times, the ScanArm will be utilised to fast track, confirmation of the dimensional alignment of new or modified sample parts against the customer supplied 3D models. Also, as Faro’s software uses graduated colour graphics to indicate the tolerance condition of components’ features, in addition to tabulated reports, we are now also able to supply customised reports containing detailed graphical information ” emphasized Robin Mills.
Robin Mills concludes. “In addition to improving our accuracy capability, the speed of operation of our new FARO ScanArm has enabled us to significantly speed-up our inspection processes. The man hours saved by the use of the FARO Edge ScanArm will ensure that our return on investment time will be even faster than first estimated.”
About Hadleigh Castings
Hadleigh Castings was founded in 1968 to provide a full aluminium casting and manufacturing service.
Over the years continued investment in technology and training has created a modern, high quality production facility capable of producing precision sand casting and gravity die casting to very close tolerances.
As a leading sand and die foundry we are Professionals in producing quality castings of exacting standards. and consistently produce quality aluminium products for major manufacturers, especially in the UK and European markets, and also for other regions in the world.
Building aircraft has always been a struggle between the size of their components and the need to craft them carefully. More than any other device, airplanes epitomize the concept that ‘the devil is in the details’ because in small errors lies the potential for great mischief such as increased drag and decreased range.
In the past, large structures such as wings, fuselages, or vertical stabilizers were difficult to make alike because there was no good way to measure them. The traditional measuring standard for objects over 20 feet was the theodolite.Although theodolite measurements can be fairly precise, they are subject to interpretation and as such are not always reproducible.With the advent of the laser tracker, precise, rapid, reproducible measuring over great distances finally became a reality.
Although laser trackers are used to align large industrial equipment such as metal rolling mills, printing presses, and power generation equipment, one can imagine that they were created expressly for the aerospace industry. A laser tracker can be set up anywhere, in a design studio or factory, and its vast operating range is large enough to capture the wing of the biggest planes ever conceived.
For the aviation industry a laser tracker provides the greatest benefits to mechanical engineering; calibrating machine tools and process monitoring. How this is done you can read in this white paper about mechanical engineering in the aerospace industry.
Learn more? Ask for an onsite product demonstration.
During this webinar – November 21st – we will explain how you can use the FaroArm’s touch enabled probe and laser line probe to improve your inspection process using Geomagic Control’s intuitive inspection platform.
The goal of this webinar is for you to discover how to eliminate workarounds during the inspection process without missing any detail.
With Geomagic Control and the FaroArm, you can create and run purpose-built inspection processes that do exactly what you need.
The presenter of this webinar is Marco Albrecht, Geomagic Solutions Technical Evangelist.
- Live demonstration via a step by step inspection process showing how FARO works inside Control
- Introduction of the Auto Batch Process
Date: Thursday, 21st November 2013
9:00 AM – 10:00 AM EDT (New York)
2:00 PM – 3:00 PM GMT+1 (London-Dublin)
3:00 PM – 4:00 PM GMT+2 (Berlin-Paris-Rom)
4:00 PM – 5:00 PM GMT+3 (Istanbul)
You can registere here for this webinar, free of charge.
Have a look and see how Mercedes-Benz uses the FARO ScanArm to design and produce its M-Class.
Jaguar Land Rover (JLR) is the UK’s largest automotive design, engineering and manufacturing employer and operates from 5 sites in the Midlands and the North of England.
To help satisfy the rapidly growing global demand for its cars, JLR plans to deliver 40 significant product actions over the next five years.
“In addition to using portable measurement systems for the validation of BIW structures, it is also used for measuring panels in both pre-production and production runs. The outstanding levels of accuracy and repeatability that we are able to achieve through our use of FaroArm Platinum and the Laser Line Probe, ensures that we can detect micron deviations from our CAD models, BIW Supervisor, Martyn Smith explains.”
Whether it’s small machined parts requiring precision diameters, alignment of large equipment or setting up machine tools, or even documenting entire buildings and environments, three-dimensional measurement data can help companies make more informed decisions and produce better quality products.
Read this white paper to learn more about the latest 3D measurement tools, how they work, and their common applications.
For access to other white papers on 3D measurement topics, follow this link.
Your FaroArm does a lot more than you might think
It measures, it scans, is slices and dices. Okay, the FaroArm has not worked its way into kitchens around the world yet, but it is used for a lot more than measuring parts and capturing geometries in 3D. In fact, you don’t have to look far to find FARO customers using their Arms in interesting ways, like preserving historical artifacts or designing crash test dummies.
No, your ScanArm will not cut through a hammer head and still be sharp enough to slice a red, ripe tomato. But, it can be used in all sorts of applications that you may not have considered. Here are a few.
Bringing history to life
The Smithsonian Institution uses their Edge ScanArm to create 3D models of ancient artifacts, including the remains of American naturalist, Robert Kennicott. Last year, the team put the finishing touches on a new bust of the explorer constructed from scan data and a 3D printed model of his skull. The Smithsonian isn’t alone in using the arm to document historic artifacts, either.
Own a CNC, waterjet, or robot? Use the FaroArm to trace the surface of raw materials and digitize the toolpath before ever making a cut, just like KMT RoboticSolutions. In this way, we predefine a precise shape and “teach” the machine with a high degree of accuracy. Then, use the arm to measure the finished part and check it for accuracy.
Neat little packages
Fitting square products into round boxes – and vice versa – is not always the most effective way to package your newest innovation. Instead, scan your products with the ScanArm, import that data into any number of design programs (here, here or here) and design custom packaging that fits just right. It’ll look better and do a better job of protecting your products for resale.
By adding a third-party camera to the ScanArm, we can combine real and digital imagery (augmented reality) to give the operator a virtual view of the parts to be inspected or assembled. Don’t believe it? See it here.
Making smarter dummies
Researchers from the University of Michigan Transportation Research Institute (UMTRSI) are helping to create better crash test dummies (not the Canadian folk-rock band you remember from the mid-90s) through their research of driver posture and anthropometry. By using a FaroArm to capture data on driver position and the 3D locations of body landmarks, engineers can design better dummies that accurately mimic the response of the human body during a crash.
Do you have a new or innovative way to use the arm that perhaps we haven’t mentioned here? Let us know in the comment section below or share it on Facebook.
Want to know more ways to get the most from your FaroArm? Contact FARO today and learn how.
The FARO Edge ArmScan will help Caterham F1 Team to optimise their in-house quality control.
The FARO arms will be utilised in two contexts. One will be to support wind tunnel tests by checking both the dimensions and the orientation of model parts being tested within the tunnel.
The other, perhaps more fundamental, will be to allow the team to bring in-house both the manufacturing and associated quality control of the ‘patterns’. These are machined from an epoxy material that are used as templates for making moulds from which carbon fibre components for the team’s cars are produced, as well as checking the dimensional accuracy of the moulds themselves.
Mecat 5 is a small but dynamic company in the heart of Piedmont which offers cutting-edge quality and technological contents in the special machine production sector.
Recently Mecat 5 manufactured special equipment for REV Aviation SpA – located in Chivasso, Torino – which Alenia uses for the construction of engine nacelles for the new Boeing 777 and 767 aircrafts.
“In addition to the production of parts, REV Aviation requires the respective dimension testing and inspection. Our need to use an adequate device derives from our client’s specific request.”, “said Isidoro Mirabella, owner of Mecat 5.
This video shows you how to reduce onsite measuring time with the FARO Gage.
As the Gage is specifically used by shop floor personnel, this video includes an example of an inspection routine at one of our clients.
For more on the FARO Gage, please visit our website: www.faro.com/gage