CASE STUDY

LK horizontal-arm CMM
inspects next-generation
automotive fixtures
RapidFit modular gauging and holding fixtures with 3D printed
locators provide major benefits in vehicle manufacture

Quality control of the fixtures is crucial. There was a need at the Leuven facility for higher accuracy
when checking fixture calibration and to achieve this, an LK HC90 40.16.16 premium performance,
horizontal arm CMM was purchased, together with the manufacturer’s CAMIO 8 multi-sensor
programming and analysis software.

RapidFit • LK HC90 40.16.16 CMM • CAMIO 8 software

 The accuracy and repeatability of the LK
CMM is very high for its large size. It can measure
two of our fixtures at a time, resulting in high
productivity in the inspection department.
Stefan Roeding, Marketing Manager, RapidFit
Materialise Group spin-off RapidFit has deployed
a horizontal-arm co-ordinate measuring machine
(CMM) manufactured by LK Metrology in
Derbyshire, UK to check the accuracy of bespoke
gauging and holding fixtures produced for the
automotive industry.
Based in Leuven, Belgium, RapidFit has reduced
costs and lead-times by making use of additive
manufacturing (AM), also known as 3D printing,
to produce workpiece locators that are added
A fixture with additively manufactured locators
being inspected on the LK HC90 40.16.16 CMM
2 RapidFit • LK HC90 40.16.16 CMM • CAMIO 8 software
to standard fixture components. The technology
enables vehicle production to be streamlined,
as innovative fixtures can be constructed with
enhanced functionality and better repeatability.
Often, this is achieved by incorporating complex
clamping elements with freeform contours
that are traditionally produced by conventional
machining, which is expensive, time consuming
and creates a lot of waste material. Integration of
intelligent, quick-release mechanisms that do not
damage the component being retained is another
possibility. Even moving elements like hinges can
be printed, as well as features such as clips, pins
and holes.
High-wear plastics are used to manufacture the
components, sometimes with steel inserts or
bushings. Alternatively, parts can be produced
from aluminium-filled nylon powder, allowing
robust elements to be printed that may be
subsequently milled and drilled to an accuracy of
± 0.05 mm.
Users of the fixtures are mainly manufacturers
of plastic and composite components for
vehicles, from relatively simple, lightweight
housings or small sheet metal parts to full body
panels, dashboards and bumpers for sports cars.
Customers include automotive OEMs such as
Audi, Bentley, Lamborghini and Volvo as well as
leading players in their supply chains, for example
Mecaplast and Valeo.

Inspection programs are generated offline using LK’s
CAMIO 8 software to maximise the use of the CMM
Shorter lead-time from receipt of order to
delivery of the fixture, especially when complex
geometries are involved, is a result of not having
to program a milling machine to remove typically
90 per cent of material from an aluminium billet,
or expending time and expense having a casting
made and then machining it.
Close-up of modular fixture inspection in progress on the LK CMM
RapidFit • LK HC90 40.16.16 CMM • CAMIO 8 software
Users are given more time and flexibility to
fine-tune their product designs and still meet
deadlines. An added advantage is that the
locators and contours are typically half the weight
of their conventionally machined equivalents and
therefore the fixture is lighter and less tiring for
operators to use.
A high degree of modularity is provided using
standard holding elements, such as the Aluquick
range from German firm, Horst Witte, to support
the bespoke 3D printed locators. The system
allows easy modification by simply replacing them,
so fixtures can be reconfigured inexpensively to
accommodate design changes.
The patented, customised products supplied
by RapidFit are of two types. Gauge fixtures are
for inspecting automotive components after
manufacture to verify their accuracy, while
holding fixtures support components as they are
built into a vehicle and measured using CMMs or
3
 other metrology equipment. Both types provide
comprehensive management of dimensional
accuracy, which is vital to the overall quality of
the final vehicle.
Accuracy is critical for RapidFit
customers
This in turn means that quality control of
the fixtures is crucial. There was a need at
the Leuven facility for higher accuracy when
checking fixture calibration and to achieve this,
an LK HC90 40.16.16 premium performance,
horizontal arm CMM was purchased, together
with the manufacturer’s CAMIO 8 multi-sensor
programming and analysis software. The machine
provides almost unrestricted access to its 4m x
1.6 m x 1.6 m measuring envelope and features
ceramic guideways and air bearings for stability at
high velocity and acceleration.
A RapidFit fixture secures a bumper as it is being assembled onto a car, providing major benefits for the vehicle manufacturer
4 RapidFit • LK HC90 40.16.16 CMM • CAMIO 8 software
A Renishaw PH10-MQ motorised indexing head
with in-quill head mount and autojoint probe
mount together with a TP200 touch trigger
probe and various extension bars formed part
of the package. The HC90 is housed in a climate
controlled metrology room and is currently
operated over a single shift.
Stefan Roeding, Marketing Manager at RapidFit,
commented, “Customers will only accept
measurement results if they trust the equipment
that generates them.
“The accuracy and repeatability of the LK CMM is
very high for its large size. It can measure two of
our fixtures at a time, resulting in high productivity
in the inspection department.
“Installation of the machine has been a big step
forward in assuring the quality of our products
before delivery and avoiding costly reworking. It
is fulfilling all of our customers’ requirements.”

Filip Dehing, RapidFit’s CEO, added “With a

worldwide sales and support network, our
company is in an ideal position to grow by
becoming a preferred partner for large automotive
companies on a global scale and by fully exploiting
new opportunities.

“Underpinning all of this is our commitment to

high quality. Our inspection department with the
LK Metrology CMM breathes accuracy, making it
A Nikon Metrology laser scanning head deployed
an important marketing tool when customers and on the LK HC90 40.16.16 CMM at RapidFit
prospects visit us.”

Offline programming fixture can take up to six weeks. The customer

is invited to the RapidFit measurement room for
maximises use of the CMM acceptance and sign-off.

A typical project at RapidFit starts with the
customer sending a CAD drawing of the
component to be fixtured and instructions on how
it should be clamped for the required application.
The fixture is virtually constructed in CATIA by
one of RapidFit’s nine design engineers and the
3D locator elements are output as STL files so that
they can be produced in one of the company’s
powder laser-sintering AM machines.
After 3D printing, the locators are assembled
with standard holding elements and a measuring
program is created in CAMIO 8, in this case
offline in RapidFit’s Kiev subsidiary, which allows
maximum use to be made of the CMM for
inspection. As each fixture is different, ease of
programming based on the original CAD file is a
critical advantage.
More recently, for checking contours faster, the
manufacturer has added laser scanning capability
to the CMM by purchasing an LC15Dx from Nikon
Metrology. It is interchangeable with the touch
probes and both are supported by LK’s CAMIO 8
software.
The technology offers twice the resolution of
camera-based optical systems, so is suitable for
quality control of RapidFit’s automotive fixtures.
It is therefore replacing relatively slow touch
probing routines in parts of the cycle that involve
collection of freeform data.

The program is transferred to the LK HC90

and the inspection cycle is run to verify that all
fixture dimensions are in tolerance. If changes are
needed, engineers modify the fixture and run the
cycle again. Measuring program changes can be
made quickly in teach mode if necessary.

Turn-around for a fixture of average complexity

is three to four weeks, although a very complex

RapidFit • LK HC90 40.16.16 CMM • CAMIO 8 software 5

About LK Metrology
LK Metrology is renowned for innovative CMM hardware and software solutions. The company’s metrology
products are used worldwide to control and improve the quality of manufactured components. Its precision
technology underpins the process chain from design, development, production and assembly through to
quality assurance in global industries such as automotive, aerospace, defence, motorsport, energy, medical
and contract inspection.

Established in England in 1963, LK Metrology has an impressive heritage in metrology dating back to the birth
of CMM technology. Founded by CMM pioneer Norman Key and his father-in-law Jim Lowther, LK Metrology
is credited with many of the CMM industry’s firsts including the first bridge-type design, first OEM to integrate
computers, first to use a touch trigger probe, first to develop inspection software, first to use all air bearings
and granite guideways, first to use carbon fibre composite spindles, first to use microprocessor-controlled
drive systems, first to produce a truly thermally stable CMM and first to produce a high-accuracy horizontal-
spindle CMM.

In 2018, LK Metrology was relaunched as an independent CMM manufacturer after several years as a division
of Nikon Metrology. Headquartered in the UK, LK’s CMM development and production are at the company’s
facility in Castle Donington. Sales and support offices are located in the UK, North America, Belgium, France,
Germany, Italy and China, supplemented by a worldwide distributor network.

Copyright © 2019. LK Metrology. All right reserved.

www.LKmetrology.com 6