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3D Shape & Defects of Car Body Surfaces

Deflectometry-based absolute 3D shape measurements of freeform reflective and diffuse surfaces

OptiGlass: Surface Appearance Quality Control Logo

On the subject of quality appearance

Quality control of car body parts has become a critical factor in the automotive industry, as competition between manufacturers is ever increasing. A customer's first impression of a car is undeniably linked to its exterior appearance, as flawless exteriors with smooth surfaces and edges are often perceived as a sign of quality and  technical superiority.

Customers determine the exterior quality of a vehicle by assessing the accuracy of the reflection of linear textures, such as trees or walls, on a vehicle's surface (mirroring the process used in quality control with fluorescence light tubes).
In a customer's mind the exterior quality often translates as an indicator of the overall build quality and thus perceived value of a vehicle.

The OptiStamp solution provides a groundbreaking new approach to quality control of vehicle body parts which far exceeds the capabilities of current solutions.

Vehicle Door Panel
Vehicle Door Panel

Horizontal stripe reflection

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Vehicle Door Panel
Vehicle Door Panel

Vertical stripe reflection

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Vehicle Door Panel
Vehicle Door Panel

Close-up of detected scratches in the absolute 3D measurement

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Vehicle Door Panel
Vehicle Door Panel

Horizontal stripe reflection

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Vehicle Hood Panel
Vehicle Hood Panel

Deflectometry-based measurement using vertical patterns

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Vehicle Door Panel
Vehicle Door Panel

Deflectometry-based measurement using horizontal patterns

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Vehicle Door Panel
Vehicle Door Panel

Absolute 3D Form Measurement with Defect Overlay

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Vehicle Hood Panel
Vehicle Hood Panel

Deflectometry-based measurement using vertical patterns

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Defect detection at early production stages of raw metal sheets

The early detection of surface defects on raw sheet metal parts is a fundamental improvement over present solutions. Until now, typical defects like dents, bumps and waviness could not be observed at the early production stages due to the parts’ rough surfaces.

An identical inspection approach for raw material and final product quality control

Traditionally, the appearance quality of raw sheet metals used for vehicle body parts could not be measured due to the surface diffusing properties and lack of specular reflectiveness of the surface. Contrary to the final vehicle body panels which benefit from a higher specular reflectance from painting and lacquering.
The OptiStamp system doesn't discriminate between both states and offers an identical measurement capacity.

A technological breakthrough

To overcome these previous limitations, Virelux applies a new deflectometric approach.
This enables the OptiStamp system direct access to absolute 3D shape measurements of freeform car body surfaces, including detection of appearance defects on specular (reflective) and non-specular (diffuse) surfaces.

Door

Door

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OptiStamp 3D measurement of a raw stamped door panel