Metrology for R&D & Product Development

Perfecting the Prototype: Why Metrology Matters in Product Design

As many manufacturers have learned the hard way,  the "cost of change" increases dramatically in later stages of the product lifecycle. By some estimates, fixing a dimensional issue after production could easily cost 1,000 times more than fixing it during the design stage.

Beyond cost, insufficient use of metrology early in development can lead to serious consequences, ranging from product recall to catastrophic failure. When embraced early in the research and development (R&D) phase, metrology and dimensional inspection can position a new product for success.

Benefits of Metrology in Product Design

In manufacturing, metrology— the science of measurement —  involves precisely measuring geometry, surface characteristics, and tolerances of parts and assemblies to ensure a product performs as it was designed to in the real world.

Below are some ways that metrology and dimensional inspection support research, development and design:

1. Improves Quality: The earlier flaws, deviations, or assembly issues are identified, the less costly they are to fix. Metrology labs use tools such as coordinate measuring machines (CMMs), laser scanners, and 3D scanning systems to ensure that a manufactured part or prototype meets design parameters and specified tolerances. If a prototype’s dimensions match the CAD model, the manufacturer can move forward with confidence that parts will perform as designed. When dimensional issues are identified early —before the manufacturer invests in production tooling — engineers have time to refine the design for optimal performance at minimal cost.
2. Reduces Risk: Use of dimensional inspection early in the design process reduces risk by helping manufacturers catch and fix deviations before the part moves into mass production when issues are far more costly to fix.
3. Allows Data-Driven Design Iterations: Rather than trial-and-error or simple visual inspection, dimensional metrology delivers accurate, objective measurement data that can be used to inform future design iterations and shorten the product development life cycle. Accurate dimensional data allows engineers to determine realistic tolerances and avoid unnecessarily tight tolerances that are more expensive to achieve. 
4. Verifies Manufacturability: While a design may look good on paper, it may prove challenging to manufacture with consistent quality. Dimensional inspection helps to ensure consistent production of quality products. As production nears, first-article inspections (FAI) can be performed on the first batch of manufactured parts as a final check of manufacturing reliability.
5. Ensures Compliance: Accurate measurement throughout the design process ensures that manufactured parts meet industry regulations and safety standards This is particularly important for products that impact safety, such as aerospace, automotive and medical device parts and components.
6. Reduces Costs: Early detection of potential design issues helps manufacturers avoid late-in-the-game tooling modifications and minimizes the risk of costly rework, scrap, launch delays, product recalls and liability issues.

Clearly, in terms of cost, quality and compliance, it pays to identify dimensional discrepancies during the R&D phase rather than after production begins — and Industrial Inspection & Analysis (IIA) can help.