Transforming Large-Scale Casting Inspection with 3D Laser Scanning

In the heavy-industry manufacturing sector, large cast components—such as machine tool bases, structural frames, and industrial housings—are critical elements that support precision, durability, and operational stability. These parts often exceed several meters in size and combine coarse as-cast surfaces with finely machined finishes, presenting significant challenges for traditional inspection methods.

Conventional techniques such as coordinate measuring machines (CMMs) or tactile gauges may struggle with accessibility, setup complexity, and coverage on such large, intricate parts. Optical 3D scanning with dynamic tracking offers a non-contact, full-field measurement solution that can significantly improve data completeness, flexibility, and operational efficiency—enabling fast, accurate inspection even in shop-floor environments.

In this context, TAJMAC-ZPS, a.s. is a leading machine tool manufacturer headquartered in Zlín-Malenovice, Czech Republic. The company has a fully integrated production system — from casting and machining to final assembly — ensuring strict quality control and efficiency. Its in-house foundry enables production of large, complex cast components widely used in heavy industries.

The Challenge: Inspecting Large Castings Efficiently

The customer faced difficulties in inspecting very large castings, ranging from 500 mm to 5000 mm in size and weighing several tons. These components often combine rough matte (as-cast) surfaces with machined glossy areas, which are challenging for conventional inspection methods.

Key challenges:

• Traditional inspection required extensive marker placement, leading to long setup times.
• Existing workflows lacked efficiency, slowing down throughput.
• The process needed to cope with operator movement and part vibration without compromising accuracy.

Technical Requirements

The project demanded a solution that could deliver:

• High Accuracy, depending on geometry and tolerance needs.
• Speed, with faster data acquisition compared to legacy methods.
• Flexibility in handling mixed surface finishes (matte and glossy).
• Full coverageof large, complex geometries, including undersides and interiors.

The Solution: Dynamic Tracking & Extended Volume

Scanology deployed its optical 3D scanning system technology to address the customer’s requirements.

The NimbleTrack wireless 3D scanning system is highly compact and agile, which is designed to redefine the precise 3D measurements of small-to-medium-sized parts. Thanks to powerful on-board chips and built-in battery power supply, its 3D scanner and optical tracker are fully wireless, enabling true freedom.

Workflow at a Glance

1. Setup – Position 3D scanner and tracking system; apply reflective markers if needed.
2. Acquisition – Scan all accessible surfaces using dynamic tracking; reposition the part for underside data.
3. Alignment – Merge multi-position scans into one model.
4. Inspection & Reporting – Perform deviation analysis and generate QA reports.

Results & Impact

The solution was validated on a 4500 mm casting, scanned from both sides with complete surface coverage.

• Faster Acquisition – Significantly faster than the previous setup.
• Dynamic Tracking Mode enabled real-time tracking of both the scanner and the part, ensuring uninterrupted scanning even when operators moved or the part vibrated slightly.
• 12 mm Reflective Markers were applied strategically to extend the trackable volume for very large parts.
• Comprehensive Coverage was achieved by scanning both sides of the casting. After repositioning, multiple datasets were aligned into a unified, watertight model.

This workflow allowed TAJMAC-ZPS to perform large-scale inspections directly on the shop floor, without compromising speed or accuracy.

The new process delivered higher efficiency and reliability, setting a new benchmark for large-scale industrial inspections.

Competitive Advantage

Compared with traditional methods such as CMMs or fixed optical systems, Scanology’s solution offers clear benefits:

• Flexibility – Supports marker-free or marker-assisted workflows.
• Speed – Rapid acquisition and automatic meshing reduce inspection time.
• Accuracy – Sub-millimeter results even on very large components.
• Simplicity – Lightweight and wireless equipment enables on-site operation.

Conclusion

By adopting Scanology’s 3D laser scanning solution, TAJMAC-ZPS successfully optimized its large-scale casting inspection process. The new workflow not only improved speed and accuracy but also enhanced flexibility, allowing the company to achieve consistent, reliable results across its heavy industry applications.