Enhancing Mold Alignment with SCANOLOGY 3D Scanning Solution

In the casting industry, the performance and reliability of molding machines are just as critical as the quality of the molds themselves. These machines are responsible for producing high volumes of castings with consistent accuracy and efficiency. Any misalignment or wear within the molding machine can directly lead to defects such as dimensional deviations, surface irregularities, or mismatched mold halves—ultimately affecting product quality and increasing scrap rates.

Traditional measurement tools often struggle in harsh environments such as high temperatures and confined spaces, especially when dealing with large and complex geometries. Manual correction procedures are not only time-consuming but also prone to errors, which can lead to costly defects in production.

As one of the key players in this field, Metal Technologies has been dedicated to delivering high-quality cast and machined metal products. The company specializes in gray iron, ductile iron, and austempered ductile iron castings, supplying critical components to demanding industrial sectors.

The Feature of the Part to Be Inspected

The inspection target was the mold-closing section of a molding machine. This included the fixed mold on the left side of the internal frame and its counterpart. These metallic assemblies contain precision-machined cavities and features that define the final geometry of the cast products.

An intermittent misalignment issue during mold closure has been observed, causing rubbing between mold halves and resulting in casting defects. This challenge has prompted the client to seek a more reliable and precise inspection method beyond manual alignment checks.

Measurement Challenges

Several technical and environmental challenges complicate the inspection process:

• High accuracy requirement: The inspection demanded a high level of precision to ensure proper mold alignment.
• Tight time constraints: Three mold pieces, each ~1 m² in size, had to be scanned within 15 minutes to minimize downtime.
• Challenging environment: High ambient temperature and limited space around the 7-meter-long molding machine made maneuvering difficult.
• Surface conditions: Metallic reflective surfaces posed additional challenges for optical scanning.

Limits of Previous Measurement Methods

• Conventional handheld laser scanner: Required cables and reflective targets, which limited mobility and increased setup time. Its relatively slow scanning speed reduced productivity, and scanning large equipment demanded frequent repositioning of the setup—making the process inefficient.
• Articulated inspection arms: Limited reach restricted access to internal or complex surfaces. Repositioning often caused loss of reference, requiring recalibration. Their bulk and weight also made them unsuitable for frequent relocation across multiple production lines.

Process Implementation

The operator positions the NimbleTrack at the first scanning location and proceeds sequentially with the three components. Dynamic Tracking ensures seamless reference even as the operator moves around the 7-meter machine. For hard-to-reach geometries, the probing function ensures no detail is missed. The entire process is streamlined, efficient, and requires minimal setup time compared to traditional systems.

Measurements are taken twice—once before the mold adjustment, and once after—to verify alignment. This repeatable, data-driven approach ensures reliable mold closure and significantly reduces the risk of casting defects.

SCANOLOGY’s 3D Solutions and Benefits of 3D Solutions

SCANOLOGY provided an advanced wireless 3D scanning solution NimbleTrack, delivering multiple advantages:

• No surface preparation required: Capable of capturing shiny or reflective surfaces without developer sprays.
• High-speed scanning: Rapid data acquisition shortened inspection cycles and minimized downtime.
• Wireless operation: Eliminated cables, improving operator mobility, safety, and flexibility in constrained environments.
• Integrated probing and scanning: Combined contact probing and non-contact scanning in one device, enhancing versatility.
• Dynamic tracking: Allowed repositioning of the tracker without losing accuracy or reference points.
• Compact and portable: The lightweight design enabled operators to access tight or hard-to-reach areas with ease.
• Screen mirroring support: Real-time process monitoring ensures accuracy and reduces the risk of missed details.

Conclusion

By adopting SCANOLOGY’s fast, wireless, and highly adaptable 3D scanning solution, Metal Technologies successfully achieved precise mold alignment verification with reduced downtime. The system delivered reliable, repeatable measurements even under challenging foundry conditions. This not only improved product quality and efficiency but also equipped the company with a scalable solution ready to support future production line expansions.