The magaz i ne abou t I n f i n i t eFocus

MEASUREMENTIN FOCUS

MEASURE FORM ANDROUGHNESS IN

ONLY ONESYSTEM

INFINITEFOCUSPROVABLEPRECISION

Eng l i s h ed i t i o n 1 , 2010 / 2011

INFINITEFOCUSVARIATIONS

OPTICALMEASUREMENTIN PRODUCTION

INTRODUCTION

4 – 7 INFINITEFOCUS

8 – 13 BENEFITS

FROM EXPERIENCE

16 – 17 TOOL MEASUREMENT

18 – 19 INFINITEFOCUS REAL3D

20 – 21 MEDICAL DEVICE

22 – 23 MATERIAL SCIENCE

24 – 25 MICRO SYSTEMS TECHNOLOGY

26 – 27 MICRO ELECTRONICS

28 – 29 POLYMER & MOLDING

30 – 31 FORENSIC

32 – 33 PAPER AND PRINT

OPTICAL MEASUREMENT IN PRODUCTION

34 – 35 IF-SENSOR, IF-PORTABLE,IF-ROBOT & IF-EDGEMASTER

MEASUREMENT MODULES

36 – 37 FORM, ROUGHNESS, SURFACE TEXTURE,AUTOMATION

TECHNOLOGY

38 – 39 PROVABLE PRECISION

40 – 41 INFINITEFOCUS ADD ONS

42 – 43 THE PRINCIPLE OF FOCUS-VARIATION

SPECIFICATION

44 – 45 TECHNICAL SPECIFICATION INCL.EXPLODED VIEW

Table of contentJANUARY 2010 /JANUARY 2011

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EditorialEvery day we are exposed to an overwhelmingflood of information. Additionally, globalized eco-nomy requires instant decisions to be made. Thecorrect focus can easily be lost or shifted towardsthe wrong direction.

Your focus is the constant manufacturing of highquality products and innovative R&D. Metrology isone of many tools you need in order to reach thesegoals. The better the tool, the faster you are ontrack and the more effective your result will be. Buthow to find the correct and lasting solution out ofthe flood of information and existing technologies?

With the first issue of FOCUSvariation, the maga-zine presenting the InfiniteFocus product line, weshowcase the focus of our work. We claim to pro-vide you with comprehensive information offeringa substantial basis for a fast, reasonable and la-sting decision. The presentation style in the formatof a high quality magazine emphasizes our out-standing innovation in both our products and mar-keting.

Enjoy reading the first issue about InfiniteFocusand evolutionary measurement!

Dr. Stefan Scherer,Alicona CEO

Dr. Manfred Prantl,Alicona CEO

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The system.InfiniteFocus is a high resolution optical3D surface metrology system for laband production.It tackles large measurement areas and volumeswith a vertical resolution of up to 10nm.

The function.InfiniteFocus offers the functionality of a microcoordinate measurement machine forform measurement and the ability to measureroughness like a surface metrology system.Form and roughness are measuredwith only one system.

The benefits.High resolution measurements on complexcomponents, various material pro-perties and varying surface finishes. Thisalso applies to specimens with small radiiand angles. In addition every measure-ment is provided with surface color infor-mation registered to the 3D data.

4 alicona I Introduction

INFINITEFOCUS :MEASURE FORM AND ROUGHNESS

WITH ONLY ONE SYSTEM

The applications.It is easy to measure micro precision parts aswell as micro and nano structures on large compo-nents. Tribology and corrosion investiga-tion are as common applications as wear andtolerance measurements in tool industry.Forensics and medical technology benefitfrom the same advantages as paper and printindustry.

The technology.Focus-Variation makes use of the limited depthof focus of an optic. The technical principle isISO-certified in EN ISO 25178 and allowsmeasurements with high repeatability includingquality information for evaluating the measu-rement uncertainty.

The know-how.”Our products become smaller and smaller.Now we can finally measure the way wetruly manufacture!“Mark Raleigh, CEO EDM

Introduction I alicona 5

Take2 isa thing ofthe past.Today form as wellas roughness of acomponent is mea-sured with onlyone technology.Focus-Variation offers the functiona-

lities of a micro coordinate measure-

ment machine with those of a

surface metrology system. This al-

lows InfiniteFocus to acquire full sur-

face characteristics since both, form

and roughness is measured with

only one system. Even across large

measurement areas and volumes.

6 alicona I Introduction

USEINFINITEFOCUS» for quantifying materialcharacteristics on anareal basis

» to measure functionalparameters on plain orcomplex surfaces

» for identifying nuancescaused by a manufactu-ring process and definingparameters for processreliability

» to measure fineroughness and smallmicro form elements

USE INFINITEFOCUS TOMEASUREFORMANDROUGHNESS

Focus-Variation is thetechnology. The result is adevice measuring largeareas and volumes with avertical resolution of up to10nm.

One system covers allInfiniteFocus is an optical high resolu-

tion 3D measurement system for qua-

lity assurance in the lab and in

production. The micro coordinate mea-

surement machine by Alicona combi-

nes all functionalities of a coordinate

measurement machine with those of a

surface measurement device. This

means that InfiniteFocus measures

form and roughness of components

with a vertical resolution of up to 10nm

- even across large vertical and lateral

measurement areas.

The technological edge to combine

roughness and form is due to the high

resolution and the very high measure-

ment point density. More than 100 Mil

measurement points enable full surface

characterisation – roughness measure-

ment in combination with form – even

across large measurement areas and

volumes. Also when measuring com-

plex shapes with steep flanks and

smallest radii the large point density en-

sures that highest resolution is achie-

ved. This allows the measurement of

dimensional accuracy on areas that

have not been accessible before and,

which cannot be measured by conven-

tional measurement techniques. In ad-

dition, the Alicona SmartFlash

technology ensures that InfiniteFocus

automatically adjusts to the different

surface properties of a specimen. This

allows the measurement of compound

materials and other topographies with

varying material appearance.

See where and what youmeasureInfiniteFocus is the only optical measu-

rement system to provide measure-

ment data perfectly registered to

surface color information. This really

simplifies the use as the operator is

much quicker in detecting a relevant

spot for investigation. Due to the corre-

lation between registered true and

pseudo color view, measurements be-

come faster and more flexible. In addi-

tion, registered surface color

information enables the accurate mea-

surement of large measurement areas.

ApplicationsUsing InfiniteFocus, smallest micro pre-

cision parts are as easily measured as

micro- and nano structures on larger

components. InfiniteFocus is as com-

monly used for investigating tribological

processes as it is for corrosion and many

other form and roughness measure-

ments. Wear measurement is as part of

quality assurance with InfiniteFocus as

reverse engineering is. Also, 3D data can

be processed with CAD for these type of

applications.

The fields of application for InfiniteFocus

are nearly unlimited: any solid surface

with a minimum roughness of only a

few nanometers can be measured.

This applies to measurements in the

field of tool manufacturing, micro sys-

tem technology, micro fluidics, material

science, medical technology, paper in-

dustry, electronics, forensics and many

more.

Focus-VariationInfiniteFocus is based on the techno-

logy of Focus-Variation. The small

depth of focus of an optical system is

used to extract depth information of a

surface. This optical technique allows

repeatable and traceable measure-

ments – including quality information to

judge measurements uncertainty.

Focus-Variation is included in EN ISO

25178.

Surface metrology and form measurement inone system

Introduction I alicona 7

Focus-Variation is one of the most innovativeoptical technologies developed in present times.It is included in the most recent EN ISO standard 25178.Focus-Variation allows high resolution, repeatable

and traceable measurements of

» form and roughness

» small radii and angles on complex forms with steep flanks and

across large measurement volumes

» surfaces made out of various materials and extreme roughness

8 alicona I Benefits

“INFINITEFOCUSIS THE KEY FOR OUR QUALITY

ASSURANCE”MARK RALEIGH IS OWNER AND CEOOF THE

MICROMANUFACTURING COMPANY EDM DEPARTMENT, BARTLETT, IL, USA.

HE KNOWS INFINITEFOCUS FIRST HAND AS A USER. HIS EXPERIENCES

WITH THE SYSTEM ARE SEEN AS A SEAL OF APPROVAL FOR THE

OPTICAL MEASUREMENT DEVICE. FROMHIS PERSPECTIVE

HE PRESENTS THE FOLLOWING UNIQUE SELLING PROPOSITIONS.

Benefits I alicona 9

» MAXIMIZE PROFIT

» SIMPLIFY COMPLAINT

PROCESSING

» OPTIMIZE PRODUCTION

» INCREASE NUMBER

OF NEW CUSTOMERS

» INCREASE DEGREE OF INNOVATION

» SPEED UP PRODUCT DEVELOPMENT

» ENHANCE QUALITY ASSURANCE

Mark Raleigh, CEO EDM Department

When components are below 100µm traditional tactile methods are no longer suitable. The deeper andsmaller the recesses produced by drills, micro milling cutters etc. are, the smaller is the probability thatthese components can be adequately measured. The EDM Department, a specialist user of hybrid manu-facturing methods now uses an optical technology that starts measuring where other techniques have al-ready reached their limits. CEO Mark Raleigh says: “Since we have integrated InfiniteFocus in ourmanufacturing process we know about details I have never seen or even measured before.”

All measurementsinclude dataregistered to the objectcolor information.360° measurement opensup completely new viewsand insights.

GAINED IN PRACTICE, FOR USE IN PRACTICE.

MARK RALEIGH SERVES

A FULL MENU OF

10 alicona I Benefits

FORM AND ROUGHNESSwith only one system“By using InfiniteFocus we can measure form and roughnesswithin the same measurement. Up to now, a contact coordinatemeasurement machine has been used for form measure-ments, for evaluating the accuracy of fit and to checkmanufacturing tolerances of our components. Forroughness measurements we have been using atraditional tactile surface metrology system.Now we have a system which covers both and whichis extremely easy to use. This has simplified our qualityassurance to an extent as we could not have visualizedbefore.“

SMALLEST RADII AND ANGLESalso across large measurement volumes

“No other optical technology offers a similar high density of measure-ment. This large amount of measurement points allows me tomeasure with a vertical resolution of up to 10nm even at largemeasurement volumes. In practice, however, this means that wecan measure even extremely small radii, angles and roughness

that were previously not accessible.”

FLANKSwith more than 80°“The products we are producing today getsmaller and smaller. At the same time,tolerances have become smaller on compo-nents with more complex forms. Conse-quently, it got rather hard to record, letalone measure the µm-dimensions thatwe actually manufacture. We haveevaluated several optical systemsand we always came to the sameconclusion: all alternative optical tech-nologies failed in measuring steep slo-pes. InfiniteFocus was the only systemwhich met its promises. We can even mea-sure flanks steeper than 80° with traceableaccuracy.”

MEASUREMENT

Benefits I alicona 11

INSPECT SURFACES WITHdifferent surface characteristics“Components often consist of a combination of different materials.In addition, depending on the manufacturing sector the differentsurface characteristics need to be measured. We rarely measureconsistant topographies, it is much more common that the manu-factured components have varying reflective properties. By usingInfiniteFocus, we have a system which measures independently of

those reflections. This is achieved by the SmartFlash tech-nology. It does not matter if the surface is smooth

or rough, matt or glossy, reflective or diffuse –the technology makes sure that the soft-ware automatically adjusts to the differentreflections and therefore exactly to mysurface.”

REGISTEREDtrue color information“InfiniteFocus is the only measurement instrument thatmeasures the topography including data point accurate color

information. Due to the optical color image we can easilylocate our position on the surface. This essentiallysimplifies measuring as the measurement range canbe identified quickly and we are much more accurateby localizing them. That is how we can identify and

measure e.g. corroded areas in a user friendly, practicaland precise way.”

COMPLETE FORM MEASUREMENTby rotating around 360°“When manufacturing rotary tools such as micro precision drillsabout 60 surface parameters influence the durability and themanufacturing result of a tool. For perfect quality assurancefull form measurement is essential. This requires that thewhole form is captured and measured in 3D. By using theReal3D technology of InfiniteFocus this requirement is achieved.The rotation unit allows me to measure components around 360°.That is how we improve surface finish, check tolerances to ensuredimensional accuracy. This has simultaneously increase processreliability in our production.”

12 alicona I Benefits

WHY THE TACTILEMEASUREMENTTECHNIQUE ISMORE OFTEN INCHECK.

NO WEARMMeeaassuurree aallwwaayyss lliikkee oonn ddaayy oonnee..

The precision of InfiniteFocus measurements isa constant. The results are completely indepen-dent from wear and usage. Instead: Long life isassured at constant accuracy.

EASY TO USEEverybody’s darling.

The use of the system is intuitive due to its easyhandling and the excellent ease of use. Thesoftware design is logical and measurement re-sults are well presented. Comprehensive exportand print options for the measurement resultsand the well structured database complete thesystem.

Simply individual.

Different measurement tasks require individualsolutions. For that reason Alicona offers a basicconfiguration of InfiniteFocus. Its functionalitycan be extended by various specimen grips andadditional measurement modules (such as thedifference measurement of two 3D datasetsand for wear and contour measurement). AlsoAlicona original add-ons such as various toolsand traceable standards are available.Theseallow the user to verify the accuracy of themeasurement results.

A real survivor.

Focus-Variation is a stable technology that of-fers high accuracy measurements in rough anddemanding environments. A robust chassiswith integrated vibration absorption ensures aminimization of external influences as dust orvibrations.

Automatic.

For a quick change between a detail and anoverview objectives do not need to be ex-changed. A manual nosepiece allows a rapidchange of magnification without any contami-nation of the optics due to dust or other influ-ences. For “deluxe” users the objectives canalso be changed automatically with a motori-zed nosepiece.

Nothing is impossible.

If an application cannot be achieved with thestandard configuration Alicona offers extralarge versions with travel ranges of 320 x 320,650 x 650 and 1000 x 1000mm. Also customsolutions are offered for 3D measurement inproduction.

Traceable high precision.

Measure large areas in high resolution anderror-free – what sounds provocative is simplefor the Focus-Variation technique. Registeredtrue color information of the 3D surface in com-bination with the high measurement point den-sity allows an error-free combination of severalsingle measurements. Instead of stitching errors,common in other techniques, InfiniteFocusdelivers traceable precision.

Easily configurable software.

Measurement tasks are easily automated.Fractures, cracks, corroded surfaces etc. aredetected, measured and quantified automati-cally. The statistical evaluation guarantees theaccuracy of the results with clear data to showwhat the surface is like. The software has beendeveloped in a way that the user can write hisown program for his measurement task.

Benefits I alicona 13

14 alicona I Markets

INFINITEFOCUS

PRACTICE

INFINITEFOCUS

PRACTICE

Image source: Technical University Hamburg –Harburg, Advanced Ceramics Group

This interdisciplinary research group has an ambitious goal: Artificial cartilage should

replace the transplantation of body tissue in the near future. The duplicate is bred on

a scratch sensitive mineral. Its surface structure allows growth and adherence.

Daniel Fritsch, Research Assistant: “With InfiniteFocus we are able to measure the com-

plete topography of a large measurement area for the first time fully automatic and,

most importantly in a non-contact way.”

Markets I alicona 15

SStteeffaann JJaacckkee,, TTeeaamm LLeeaaddeerr ooff

QQuuaalliittyy AAssssuurraannccee,, FFeettttee

16 alicona I Markets

MEASURE EFFICIENCYA 5-axis milling machine isused for investigating materi-als with low machinabilitysuch as oxide ceramics. WithInfiniteFocus the resistance towear, tear and grain quality ismeasured. Grinding pins aremeasured before and after thetest series.

Image source: ETH Zürich

FORM AND ROUGHNESS IN TOOL INDUSTRY

Is my tool conforming to the required geo-metries? Where are the hidden form devia-tions to the CAD-dataset located? Does mycutting edge deliver the required machiningresult? Is my manufacturing result repro-ducible? What about my process reliability?How long can I use my tool until I have toexchange it due to wear?

The needs and the initial positionAs a manufacturer or user – the catalog ofrequirements in quality assurance is long:Wear measurement, tolerance measure-ment, reduction of down times, increase ofprocess reliability, improvement of repro-ducibility etc. The change of manufacturingconditions is an everyday challenge. Tole-rances become tighter, whereas cost pres-sure gets higher and geometries to bemanufactured become more complex thanever. Steep flanks, varying reflective pro-perties and small radii are part of the dailybusiness.

It could be assumed that these conditionsbecome an obstacle in quality assurance.Not because production staff fails in ma-nu facturing predefined tolerances in aµm range. This is rather because beforeInfiniteFocus there was no adequate toolavailable to measure and consequentlyprove that tolerances are actually met.

How formerly immeasurable geometries became measurableWorldwide leading manufacturers of precision tools such as Bass or Sut-ton tools share one view. “Since we have known Alicona we measuregeometries that were not measurable before.” This is true for cuttingedge measurement, tool surface measurement in the µm-range andcomplete form measurement of tap tools. Even across large verticalscanning ranges.

The solution and its advantagesManufacturers such as Bass or Fette areone step ahead compared to their compe-titors by using InfiniteFocus. Martin Zeller,Bass CEO, is confident about the most im-portant qualities of the optical 3D microcoordinate measurement machine: “Wenow measure form as well roughness ofour tools. This is an ideal combinationwhich enables us, amongst other benefits,to perform roughness measurement of cru-cial surface features that have not beenaccessible before. This now allows us totrace back processes, and, as a result, totake the right measures in order to stan-dardize processes.” This is a relevant basisto create reproducibility. “Reproducing onepart exactly as the next is getting more andmore important for the enforceability of themarket”, states Zeller about his competitiveadvantage.

The technical facts and figuresA vertical resolution of up to 10nm evenwhen measuring steep flanks or varying re-flective properties make InfiniteFocus a po-pular measurement instrument. Therepeatable measurements of radii as smallas 2µm and flanks greater than 80° cannot

be achieved by any other optical or tactiletechnique. The technology of Focus-Varia-tion allows high resolution verification ofform, orientation and surface roughness.Not to miss one of the most outstandingfeatures of the system, as Martin Zellerpoints out: “I don´t know any other systemthat covers as large of a vertical scanningrange as InfiniteFocus!” This enables the user to meet position-,form-, orientation- and diameter tolerances.Normally at least two systems are neces-sary to reliably and completely measurecomponents. By using InfiniteFocus usersare working with only one system tomeasure roughness as well as form –length, diameter, radius, angle etc.

““TThhiiss mmeeaassuurreemmeenntt ssyysstteemm iiss aanneennoorrmmoouuss iimmaaggee bboooosstt.. IInnffiinniitteeFFooccuuss iiss aa hhiigghh--eenndd ssyysstteemm.. IItt’’ss tthhee nneewweesstt aanndd mmoossttmmooddeerrnn oonnee tthhaatt eexxiissttss..””

SStteeffaann JJaacckkee,, Team Leader Quality Assurance,Fette

Markets I alicona 17

””OOnnee ooff tthhee mmoosstt ddiissttiinnccttiivvee ffeeaa--ttuurreess ooff IInnffiinniitteeFFooccuuss iiss iittss vveerrttiiccaallssccaannnniinngg rraannggee.. II ddoonn ´´ tt kknnooww aannyyootthheerr ssyysstteemm tthhaatt ooffffeerrss tthhiiss llaarrggeessccaann hheeiigghhtt!!““

MMaarrttiinn ZZeelllleerr,, CEO BASS

REALITY FROM ALL DIRECTIONSMEASUREMENTS OUT OF EVERY PERSPECTIVE USING INFINITEFOCUS REAL3D

As is often said, one of the most significant advantages of optical measurement techniques is theability to make reality visible. To see and measure a surface as it really is opens up completely new opportunities. However, up tonow the metrological recording of a surface in 3D was restricted to the 2D aspect of topography.InfiniteFocus Real3D now allows the true surface to be viewed and measured from every view point.The Real3D rotation unit, that rotates drills, milling cutters and other rotary symmetric componentsup to 360° enables the complete form measurement.

18 alicona I Markets

REALITY FROM ALL DIRECTIONS

A SELECTION OF MEASURABLE PARAMETERS WITH INFINITEFOCUS REAL3D» Surface roughness

» Rounded edge

» Flank angle

» Major diameter

» Relief

» Chip angle

FORM MEASUREMENT…… is used for measuring regular geometries and curved surfaces. Automatic fitting of spheres, cones andcylinders allow the visualization and form measurement of tools and other components. Also, deviation fromtarget geometry become clear.

CONTOUR MEASUREMENT…... allows the measurement of angles, distances, circles, incircles, circumcircles, thread pitch etc. from everyperspective and oblique position. Profile contours are measured within a few seconds.

DIFFERENCE MEASUREMENT…… shows wear and deviations to a CAD-dataset. The measurement is simple: the geometry of a tool ismeasured before and after use, the difference is then automatically measured. It is simple in use and, precise in result.

Requested by industry and developed by Ali-

cona: full form and contour measurement of

drills, milling cutters and other tap tools in 3D

with only one measurement. This is how the

supplier of optical 3D micro coordinate measu-

rement solutions has catapulted itself into the

top of this market segment.

The measurement of tool surfaces from only

one perspective is no longer efficient due to the

complexity of structures and geometries. As a

result, conventional techniques do not allow the

measurement of parameters such as relief, un-

dercuts and edge radius. InfiniteFocus Real3D

not only fills this gap, the innovative technology

also allows the automatic difference measure -

ment of a manufactured component to the

corresponding CAD-data. Also, tolerance mea-

surement to ensure dimensional accuracy and

reverse engineering is provided.

Markets I alicona 19

MEASUREMENT OF FORM, DIFFERENCE AND CONTOUR

MEASURE COMPLETE FORM AND ROUGHNESS OF TAP TOOLS

ROUGHNESS MEASUREMENTMATTERS FOR

DENTAL IMPLANTS

20 alicona I Markets

The quick adhesion with thejaw bone is dependent on theprotein binding capacity of theimplant.

The surface characteristics of a dental implantare crucial as it is the decisive factor for thesuccessful, and permanent, adhesion with thejaw bone. In order to grow together quickly andsustainably, the surface of the implant has tohave the necessary characteristics to allowprotein binding. Optical 3D measurement withInfiniteFocus provides the numerical verificationof this and consequently the verification as towhether the implant has the required surfacequality for a successful treatment. Due to the large measurement area this mea-surement can only be meaningful if areal, andnot line based measurements are used. As asupplier of areal based 3D measurement acrosslarge areas Alicona is an innovative pioneer inthis field.

Measure roughness at the rootof the thread and steep flanks

“Everything that is in contact with the boneneeds to be measured. And it is really impor-tant that I can also measure the roughness onthe root of the thread,” states Dr. Frank Rupp.Rupp is the head of the department Prostho-dontics (which is a section of Medical Materials& Technology, directed by Prof. J. Geis-Geistorferat the University Hospital Tübingen, Germany)and an expert in the field of surface modifica-tions of implants.

He has focused his investigations primarily onthe condition of the surface of the implant inorder to ensure the best possible bone inte-gration. InfiniteFocus is for him the system

that produces the best results of are basedroughness measurements. “We do not knowabout any other system that delivers as soundstatements across such large measurementvolumes,” states Rupp. Results already conformto ISO 25178 and provide not only linear butalso area based measurements. The user notonly acquires more information about the sur-face but also has the advantage of higher re-peatability and traceability. “3D measurement of the surface performedwith InfiniteFocus allows us to define the corre-lation between the topography of the implantand its performance in the body providing moresubstantiated results, with numeric values. Thisenables us to draw conclusions about the biolo-gical behaviour; and with this we can optimizenew materials,” Rupp continues. This optimi-zation also includes the inspection of the corre-lation between implant topography and thewetting behaviour. The aim is the developmentof implants assuring that the topography positi-vely effects the distribution of red blood cellswithin only a few minutes.

Larger surfacesmeasured faster

In comparison to other traditional technologiesthe results from the optical measurement sys -tem are not only more significant but also moreaccurate, faster and therefore more cost effi-cient. Frank Rupp knows this from his everydaywork: “Measurements with a scanning electronmicroscope are time consuming and complexdue to the complex sample preparation. Using atactile system one is restricted by the deflectionof the stylus tip. For thread implants where Ialso need to measure on the root of the threadthis technology is not useful at this point.”

All parameters in a single measurement

Measuring cost efficiently is also significant asseveral relevant parameters can be measuredwith one system. As a measurement systemthat combines all functionalities of a roughness-and form measurement device InfiniteFocusalso offers the functionalities of an optical pro-filometer and a micro coordinate measurementmachine. With only one measurement systemthe complete range of classical surface metro-logy (roughness measurement) and coordinatemeasurement technique (for form measure-ment) is covered. Even on complex forms withvarious surface characteristics a resolution ofup to 10nm can be achieved on large verticaland lateral scan ranges.

360° measurement for full form measurement

Meaningful surface characterization requires thefull form measurement of the whole implant.This is achieved by the optional rotation unitwhich provides a 4th axis to allow 360° measu-rement. This is how the InfiniteFocus Real3Dtechnology allows the manufacturers to mea-sure the thread pitch and therefore prove the di-mensional accuracy. Also form deviations to areference object are measured automatically.This is achieved by difference measurementbetween a component and CAD-dataset deter-mining the variances to the nominal.

Markets I alicona 21

Roughness measurement on a tooth implantAreal roughness measurement on the root of thethread of a tooth implant measured with the opticalmeasurement device InfiniteFocus

3D denture moldingInfiniteFocus also achieves si-gnificant results across largemeasurement areas, and volumes, in high resolution and with a high measurementpoint density

360° measurement of a tooth implantBy using the Real3D technology implants are measured around 360°

“We do not know about any other system that deliversas sound statements also across large measurementvolumes.”

Dr. Frank Rupp

Prosthodontics at

University Hospital

Tübingen

CAUSE AND

“InfiniteFocus closes the gap between classical 3D-coordinatemeasurement techniques and roughness measurement.”

22 alicona I Markets

Area based roughness measurement of toothflanks.Compared to tactile measurement, the FZG notonly benefits from more robust results but alsoby an improved characterization of the surfaceproperties. The large lateral and vertical measure-ment range allows the 3D visualization of a wholetooth. This enables the research centre to performa setactual comparison of flank modifications.

Examination of gear flank failures on the example pittings and micro pittings.Pittings and micro pittings are classic material fati-gue damages on the tooth flanks. With InfiniteFocusthe damaged area of the tooth flank can be quan-tified. Unlike tactile measurement the area close tothe root of the tooth is by now accessible withoutdestruction.

InfiniteFocus in fundamental tribological research: Volume measurement of micro structured polished discs.The lubricant gathers in the lasered structures andis carried through the elasto-hydrodynamic contact.The improved lubrication can reduce the frictionin the contact. With InfiniteFocus geometries andvolumes of such micro structures can be mea sur -ed to determine the influencing parameters andto secure process reliability of new manufacturingprocesses. Complex reflection properties are nochallenge: “With the X-SmartFlash technology eveninhomogeneous surfaces with varying reflectionproperties can be measured repeatable and inhigh resolution,” Richard Bäumler.

The load-carrying capacity of gear drives isaffected by the used material, the micro geo-metry on the material surface, the topography ofthe tooth flanks, and its lubrication.For these reasons the Gear Research Centre(FZG, Technische Universität München, Germany)has chosen the InfiniteFocus as it can measureform and roughness on former inaccessibleareas. Richard Bäumler, research assistant atFZG says: “We are now able to measure areasthat are not accessible by common tactile mea-surements devices. A roughness measurement,for instance, only makes sense if the measure-ment can be performed orthogonal to the grin-ding direction. Because this grinding direction isnormally in the direction of the face width, thegear has to be cut in sections for a measure-ment with a tactile stylus tip. Now we quantifythe roughness and the grinding marks in highresolution and in a non-destructive way.” Incontrast to common tactile roughness measu-rements, InfiniteFocus also measures largecomponents 3-dimensionally. “We not only be-nefit from more robust results, but also by abetter characterization of the surface. The largelateral and vertical scan areas allow us themeasurement of a complete tooth flank,” saysBäumler. “This, for example, opens up the op-portunity to perform deset-actual comparisonsof tooth modifications. InfiniteFocus thereforecloses the gap between the classical 3D coor-dinate measurement and roughness measure-ment techniques.”

IINNFFIINNIITTEEFFOOCCUUSSAAPPPPLLIICCAATTIIOONNSS IINN AAUUTTOOMMOOTTIIVVEE IINNDDUUSSTTRRYY

In addition to surface measurement and failureanalyses of gears, the 3D measurement deviceis also used for the examination of automotivecomponents. Typical applications are the measurement ofmultiple disk clutches or synchronizers as theyare used for example in motor vehicle gears.The operational behaviour is influenced by thefriction pairing and the friction surface grooves.For this reason the measurement of surfacestructures and the characterization of frictionsurfaces with appropriate area based parame-ters are important. “In order to optimize functionand durability of the various elements, we have

to know the friction behavior and to what extentit is influenced by the topographic parameters,”explains Richard Bäumler.

Markets I alicona 23

The Gear Research Centre (FZG)is part of the Institute for Machine Elements at theTechnische Universität München. The focus of re-search activities are drive systems and components.In accordance with the specific purposes of the re-search project, the whole object (transmission) orone element out of it (e.g. gear wheel, bearing) areinvestigated. Since the beginning of 2010 the highresolution optical 3D surface metrology systemInfiniteFocus is frequently used and is also availablefor service cooperation.Contact: Professor Dr.- Ing. Bernd-Robert Höhn,fzg@fzg.mw.tum.de, www.fzg.mw.tum.de

INFINITEFOCUS IN MATERIAL SCIENCE

INFINITEFOCUS AT A GLANCE:

”IN CONTRAST TO TRADITIONAL TECHNIQUESINFINITEFOCUS OFFERS THE FOLLOWING ADVANTAGES:

» Form and roughness are measured across large lateral and vertical scan ranges in only a single measurement

» Characteristic surface parameters are measured on areas that cannot be accessed by tactile systems (e.g. roughness measurement orthogonal to the grinding direction of the tooth root)

» InfiniteFocus offers the opportunity of a set-actual comparison (e.g. flank modifications of gears)

» ”Soft” surfaces and materials also used for gears such as polymers and bronzes as well as sintered or organic friction linings of disk clutches and synchronizers can be measured without influencing/damaging of the specimen

» InfiniteFocus measures highly structured surfaces and materials with complex reflection properties.”

Richard Bäumler, FZG

Determination of roughness and topography at the tooth root.The tooth root load-carrying capacity is also influ-enced by the surface characteristics in this area.Grinding grooves in the intersection between toothflank and root of the tooth may reduce the toothroot load-carrying capacity which can result intooth breakage. With InfiniteFocus roughness andgrinding grooves are quantified in a non destructiveway.

MICRO COMPONENTS:

Automatic comparison measurement to a CAD dataset

24 alicona I Markets

LARGE ACHIEVEMENTS

ON SMALL COMPONENTS.”With InfiniteFocus, I am ableto measure, in a non-contactmethod, small radii of microform elements and tools in ahigh resolution. It is fantastichow well this works. Also onmicro structured surfaces,the form measurement re-sults are outstanding andallow the measurement ofmicro milled surfaces with adepth of only 10µm. Thecombination of a surfacemeasurement device andform analysis system has in-deed been achieved.”

Prof. Jörg Seewig, Head of Institute for

Measurement and Sensor-Technology,

TU Kaiserslautern

MICRO COMPONENTS:

The smaller geometric forms of microstructured components become, the higheris the challenge in meeting and measuringthe required tolerances of bores, gates,grooves and other forms. Also, tribologystudies on friction surfaces with high pre-cision geometries have become increa-singly important. Exceptional surface quality with a dimen-sionally accurate geometry are the basisfor low wear of e.g. micro bearings ormicro gears.

The repeatable and high reso-lution measurement of micromanufactured componentshas become increasingly im-portant in quality assurance.It is mainly the surface of different materi-als that is a challenge for optical measure-ment devices: In practice the mostcommon topographies are of high-tensilecomponents such as carbide, carbon, ce-ramics and hardened steel. These materi-als often show varying reflective propertiescombined with complex forms and steepflanks. By using InfiniteFocus, manufactu-rers have a system that measures inde-

What does a cell phone, a subnotebook, a nearly invisible hearing aid and amedical device have in common?Their miniaturization.Complex components such as gears or whole micro pumps are now com-monly manufactured in the µm range using milling, eroding or injection mol-ding. The challenge is to measure these “intelligent miniatures” in order toverify the quality. But that is not enough – it is also necessary to have effec-tive and traceable 3D surface measurement and characteristics that docu-ment the quality of the surface simultaneously with its form.

pendently of those reflections. The softwareautomatically adjusts to the different sur-face conditions and delivers repeatablemeasurement results.

When small parts becomewide eyed:Created for the world ofminiaturizationInfiniteFocus enables the radius and anglemeasurement of flanks exceeding 80°:This is a function which is especially im-portant for the measurement of, e.g., gearsand threads. At the same time the high measurementpoint density ensures high repeatabilityeven with challenging measurement condi-tions. This repeatability is very important ifthe 3D measurement data is used to boostprocess reliability.The InfiniteFocus high tech measurementtechnique has great qualities so that theproducts in the field microsystem techno-logies do not just become smaller, but alsobetter, and produced in a more economicway: InfiniteFocus provides nearly endlessopportunities in this field.

TYPICAL APPLICATIONSWITH THE OPTICAL 3D MICRO COORDINATEMEASUREMENT MACHINE INFINITEFOCUS ARE:

» MIM (Metal Injection Molding) & CIM (Ceramic Injection Molding)

» 3D measurement of micro structured surfaces and quality assurance of micro milling processes

» Quality assurance of micro injection molding of metal and polymer

Form measurementto check dimensional accuracy

Difference measurementto reference geometry

Markets I alicona 25

Assembled bare die in 3Dwith registered true color information.

26 alicona I Markets

WITH INFINITEFOCUS FROM THE FIRST TO THE LASTPRODUCTION STEP

MICRO ELECTRONICS:

During the various manufacturing proces-ses the InfiniteFocus 3D measurementsystem enables the high precision, non-contact and non-destructive measurementof…

» dispensing of the glue with its three dimensional extension (volume),position and form

» lateral position of the assembled bare dies in x- and z-direction

» twisting angle of the bare die

» tilt of the bare die compared to the substrate or lead frame

» distance of the bare die compared to the substrate or lead frame

» form and orientation of the wire bond loops (typical gold wire diameter 20 – 30µm)

» micro characteristic and geometry of wedge bond (substrate side) and nail head (die)

The 3D geometry in addition as well asthe surface characteristic (e.g. roughnessof the contact pad) of the substrates andlead frames that are assembled can bemeasured.

InfiniteFocus is also used in production forthe measurement on random bases. Theadvantages for the electronic manufactu-rer are reliable and well documented qua-lity, security and reputation. But most of allhe benefits from reduced manufacturingcosts and a stable manufacturing process.

3D surface dataset of a glue crossWith InfiniteFocus volume, position and form are measured.

Markets I alicona 27

3D form measurements of wire bonds.Also, the maximum height is measured.

Micro characteristics of wedge bond on substrate.InfiniteFocus measures non-destructive and the complete geometrical characteristic: depth, cross section, radii, angle….This is how the stability of the connection is numerically verified.

POLYMER IS AS WELL.

Profile measurement of a flow channel in a thermo foil.

Excerpt from a paper composed by Josef Stirnimann, inspire AG: “The opticalmeasurement technique Focus-Variation is effective for measuring geometry,form and especially roughness at the root of rather tight channels. In a shorttime significant information about the impression of the coning die on the com-ponent and the flow behavior can be obtained.”

insipre is a joint initiative of Swissmem, the Swiss Federal Institute of Techno-logy Zurich (ETH) and the Federal Office for Professional Education and Tech-nology (OPET). Image Source: Laboratory for MEMS Applications at UniversityFreiburg.

28 alicona I Markets

POLYMER IS AS WELL.

InfiniteFocus is a well established sys -tem to determine which regions of thecooled injection molded component aredifferent to the target geometry of theinjection mold. Numerical data of shrink -age are provided automatically and in ahigh resolution, even at steep flanks andsmooth reflective surfaces. Also, vari -ance analysis between the molded com-ponent and its accordant CAD dataset isperformed. InfiniteFocus registers thetwo datasets, calculates a 3D differencemodel and displays the difference as a 3Dcolored dataset. Variances can then be seenin color and numeric data are providedthroughout statistics. By checking thedimensional accuracy also surface defectssuch as sink marks can be easily verified.

Measure form androughness with only one system:The strategy for success in (polymer) industryForm and roughness measurement arerelevant for defining the optical proper-ties of solid objects. The roughnessmeasurement ensures that e.g. a grai-ned surface will give a homogeneousview with consistent gloss value. Thegloss that overlays the roughness ismeasured using the surface texturemeasurement and the form subtraction.This can only be achieved by an areabased measurement technique as linear

techniques measure only one profile andtherefore do not provide the density ofm e a s u r e m e n tpoints required forsuch measure-ments. In contrast,InfiniteFocus mea-sures area basedacross large mea-surement fieldswith a high den-sity of measure-ment points. Thismakes the instru-ment ideal forquality assurance.

Micro die-casting: geometry, surfaces andthe dimensional accuracyof components demandan optical 3D measure-ment techniquePolymer components, as in other indu-stries, are becoming smaller. The form isbecoming increasingly complex due to theextremely small radii and nearly verticalslopes of e.g. molded components. Also,surface reflections are rather complex dueto variation in material properties. Thesefactors challenge measurement techni-ques for quality assurance.The InfiniteFocus, as a surface and form

Markets I alicona 29

measurement device, is able to meetthese challenges providing the informa-

tion required in thisfield.Micro systems, nowused in medicine,te lecommunicat i -ons, electronics,fluidics, sensortechnology andmany others requiredetailed surfacestructure measure-ment, also knownas roughness, inaddition to the mea-surement of form.

Whereas the dimensional accuracy isassured by the form measurement, theroughness measurement is relevant forthe functionality of the whole compo-nent. Prof. Richard Leach, Principal Re-search Scientist from the NationalPhysical Laboratory (NPL), commentsabout the significance of roughnessmeasurements: “In many cases thefunction of a component can be definedor predicted. It can for example be in-spected how a component reflects light,how fluid material reacts or how two be-aring surfaces move or interact.” TheFocus-Variation technology is effectivelyused wherever micro structures need tobe measured even in the nanometerrange.

”In many instances the functionality of acomponent can be defined or predictedby using a roughness measurement. Itcan, for example, show how a componentreflects light, how fluid flows over a ma-terial or how two bearing surfaces moveor interact. The roughness measurementenables the design engineer to specifi-cally manufacture a component that com-plies with the desired function to a greatextent.”

Professor Richard Leach, Principle

Research Scientist, NPL

Sometimes, form has to “disappear” in order to measure the surface roughness. This is achieved by the InfiniteFocus measurement module “Form Removal”.

30 alicona I Markets

Volume measurementof a knife holder

Detail of knife-holder

Human bone in 3D

MEASURE - DON´TSNIFFLE

AROUND!INFINITEFOCUS

INFINITEFOCUS

Firing pin in 3Dwith registered color information

Some typical fields of forensic expertise arePathology, Anthropology, Toxicology, Chemistry,Balistics, Fibers, Documents, Handwriting, Nar-cotics, Explosives, DNA, Marks etc.

RENÉ PIETERMAN, FORENSIC SCIENTIST ANDSPECIALIST ON INVASIVETRAUMAS, GIVES AN INSIGHT INTO HOW 3D SURFACE METROLOGYCONTRIBUTES TO CRIMEDETECTION.

Why is 3D surface measurementnecessary for crime detection?Why is InfiniteFocus the appro-priate tool for you?Modern forensics cannot work without 3Dsurface analysis. Our department has to ex-amine all kind of features related to tools, ob-jects, weapons etc. We also deal with markson victims’ bodies. InfiniteFocus was purcha-sed for a specific reason. We were looking fora system for the examination and comparisonof tissue, bones etc. of human corpses withtools, objects, weapons etc. Particularly, thesystem is used to measure tissue and bonedamage and the corresponding implements ofthe crime.

How would you describe the typi-cal surface condition of bones andtissue?When investigating human or animal bones,we usually face rather difficult surfaces thatshow very steep flanks. Also, weapons orsynthetics with reflecting metals were difficultto view and measure before we worked with

The Netherlands Forensic Institute is under the jurisdictionof the Dutch Department of Justice and has about 40 areasof expertise. InfiniteFocus is used for many types of casesthat are investigated for the police, lawyers, the ministry ofarmed forces etc.

InfiniteFocus. This is the main reason why wepurchased the Alicona measurement device. Itis the perfect tool to measure in a high resolu-tion even with difficult surface conditions.

What other surfaces are measuredwith InfiniteFocus?As the system can be used for most surfaceswe use it for various applications. Conse-quently, the type of materials investigated byInfiniteFocus is numerous and includes the 3Dmeasurement of metals, wood, synthetics, bul-lets, tape, tissue, bones etc.

What are the special benefits of thesystem? What is in your opinionthe most distinctive feature?One of the most important aspects for ourwork is light and illumination. The combinationof axial and ring light enables the high resolu-

René Pieterman Department of Physical and Chemical Technology Expertise Marks / Microanalyse Invasive Traumas

Markets I alicona 31

tion measurement of the various reflective sur-faces. Also, the system fills the gap betweenregular optical microscopes and the SEM. WithInfiniteFocus, we are now able to measuredown to a resolution of 10nm!

Is registered 3D color informationoffered by InfiniteFocus relevant toyou?This is definitely one of the most importantfeatures when it comes to reporting to judges,prosecutors, lawyers, police etc. Color infor-mation reinforces our findings and resultingconclusions.

INFINITEFOCUS

32 alicona I Markets

The inspection of missing dots is a standard application for InfiniteFocus. In the optical color image missing dots are clearly visible.

INFINITEFOCUS:MEASURE PAPER AND DISCOVERNEW ROUGHNESS!

Markets I alicona 33

One of the most decisive factors of the pa-pers’ printability is its topography. Besidesheight differences and local “craters” of thesurface, the smoothness highly influencesthe complete color application and qualityof a print image. 3D measurements withInfiniteFocus are performed to significantlyincrease the paper´s printability.

Use InfiniteFocus and ob-tain information about theprintability of a surface.The printability of paper is primarily depen-dent on the roughness of the surface. Tra-ditional roughness measurement methodsusing indirect measurements of only oneprofile do not provide any information aboutits printability. Dr. Rainer Klein from the PTSHeidenau, Germany: “Traditional techni-ques such as Parker Print Surf or Bendtsenare not really appropriate for modern printtechniques. This is due to the fact that theydon´t provide a real description of the sur-face on the basis of topographical parame-ters.” In contrast, InfiniteFocus provides an“all inclusive” area based measurement ofthe surface: directly, and contact free. Thisprovides a diagnostic and numeric charac-terization of the surface including the de-termination of the local homogeneity of thepaper. Also, advanced quality assurance isprovided as InfiniteFocus is used to verify

FULLY AUTOMATIC DIRECT ROUGHNESS AND SMOOTHNESS MEASUREMENT IN PAPER AND PRINT INDUSTRY.

measures that are carried out to increasethe paper´s smoothness. This is how e.g.calendaring can be optimized on a numeri-cal basis.Even on highly reflective paper surfaceswith steep slopes, Focus-Variation achievesa vertical resolution of up to 10nm. 3Dmeasurements are performed directly onthe optical color image. This is becauseboth the topographic and color informationare registered to the 3D data file. With twomouse clicks a profile is extracted acrossthe measurement region. This visual corre-lation between the color image and theareal 3D depth information make the mea-surement with InfiniteFocus precise, signi-ficant, flexible and self-explanatory.InfiniteFocus not only measures along asingle profile but on an areal basis. Thefollowing information can be obtained:

» Amplitude parameters for the description of height distribution

» Spectral analysis with auto correlation parameters

» Gradient distribution for identifyingthe frequency and distribution of certain surface characteristics

» Fast Fourier Transformation (FFT) for the analysis of marks on the surface

The topography of paper has an impacton the results of several manufacturingprocesses, for example on the final printquality. In the case of graphic papers for offsetand gravure printing, insufficient paper to-pography affects the quality of print re-sults. Indirect measurement techniquessuch as Parker Print Surf or Bendtsen arecommonly used even though they are notreally appropriate for modern printingtechniques. This is due to the fact thatthey provide no real descriptions of theactual paper surface based on topogra-phical parameters. With InfiniteFocus we are able to measurethe real roughness at high vertical resolu-tion and obtain very detailed informationabout the topography of papers. In addi-tion, the brilliant depth of focus is an ex-cellent tool for efficient troubleshooting.

Dr. Rainer KleinCompetence Centre for Surface Finishing

and Functional Surfaces, PTS Heidenau

The surface topography of paper provides information about its printability, its opticalproperties and about the potential printing quality. InfiniteFocus as a non contact opti-cal measurement system measures directly also large areas and provides a correlationbetween the paper´s surface roughness and its printability.

InfiniteFocus is also used to measure the pits on a gravure cylinder.The depth and width of the pits can confirm if a uniform application of ink is possible.

The optical 3D measurement device InfiniteFocus providesthe ability of comprehensive areal measurement of coatedand uncoated paper.

The core of production integrated mea-surement with InfiniteFocus is always theFocus-Variation technology, with the“packaging” adjusted to the application. Nomatter which InfiniteFocus version is used– the individual use, depending on theapplication, provides certain synergiesleading to cost effective measurement. For the user this means that minimumeffort provides maximum quality assu-rance. Methods proved in development orin the lab are easily duplicated in-line. Withits flexible and modular hardware system,InfiniteFocus bridges the gap between thelab and production.

Geometries have become smaller and more complex, tolerances tighter andprocess reliability has become a key question. Integrated quality assurancerequires provable and traceable measurements. With InfiniteFocus, a non de-structive measurement solution is offered in various options. This is Alicona´sanswer to the demand for faster, high resolution and traceable measurements.

The industrial capability ofInfiniteFocus is based onthe following facts:

» Simple automation of sensors on large measurement volumes withcomfortable working distances

» Proven stable technology

» The effective export- and import functionality of data transfer allowing quick evaluation of measurement results irrespective of the operating conditions (external light, temperature fluctuations, vibration)

» Simple integration into the process due to clear and defined interfaces

Special solutions for specialapplications: The IIFF--XXLLaarrggee 11000000 systemoffers a travel range of1000mm x 1000mm.

34 alicona I Production

The IF-Robotmeasures roughness, form andgeometry of large componentssuch as aircraft turbines. Robotsupported measurements alsoallow difficult to access surfacecharacteristics to be quicklyand easily measured.

IF-Portableis used for mobile applications: A movable mea-surement station that can be used wherever it isneeded.

“The request is straight-forward and challenging at the same time:Metrology used in research and quality assurance should be also applicable in production in an easy way.”

Dr. Stefan Scherer, CEO Alicona

Production I alicona 35

The IF-EdgeMaster automatically measures form, edge and radius ofinserts in production. It offers easy handling with a special coarse drivethat simplifies focusing on the insert.

is “made to be tough”, temperature stable andinsensitive to vibration. This makes the sensorsuitable for production environments. Its highoperating speed and large measurement rangemakes the sensor a universal system. Even oncomplex surfaces, large measurement areasand measurement volumes, both roughnessand form are measured in high resolution. Astrain-relieving plug on the sensor head withcables for drag chain use allows simple inte-gration in production. The SmartFlash techno-logy enables a vertical measurement speed ofseveral mm per second across large measure-ment ranges. The fast cycle times make theIF-Sensor a versatile measurement device forproduction integrated quality assurance.

measures roughness, form and geometry oflarge components such as aircraft turbines orengine blocks in high resolution. The measure-ment system combines the flexible positioningof a 6-axis robot with the measurement capa-city of the optical sensor. The analysis of de-fects, tolerance and corrosion analysis are

standard applications along with the measure-ment of orientation including the repositioningaccording to the CAD dataset. Using this, for ex-ample, laser based micro machining processesare assured.

is lightweight, robust, mobile, fast and costeffective. The system has been developed as amobile and flexible measurement station whichcan be used wherever it is needed. It is availa-ble as an alternative to a permanently installedmeasurement solution. One of the most com-mon fields where it is used is platen inspection. As for all InfiniteFocus systems the change ofobjectives is achieved with a nosepiece fittedwith several objectives increasing the resolutionof the measurement results. This removes error-prone adjustment and time consuming recali-bration after an objective change becomesobsolete.

is a system for fully automated measurementsof form, edge radius and chipping on the edgeof inserts in production. Clearance, wedge andchipping angle, chipping (and alternativelyroughness), positive and negative bevel as wellas basket arch form are measured.

As a real “production professional“, the IF-EdgeMaster» measures the edge in high resolution

resulting in robust and accurate measurement of chipping edge and roughness

DEPENDING ON THE MEASUREMENTTASK, THE FOLLOWING INFINITEFOCUSOPTIONS ARE AVAILABLE:

» InfiniteFocus as a universalsensor: IF-Sensor

» InfiniteFocus as a robotic measurement system: IF-Robot

» InfiniteFocus as a mobile solution: IF-Portable

» InfiniteFocus for cutting edge measurement:IF-EdgeMaster

» InfiniteFocus for larger and heavier components: IF-XLarge

» measures large vertical scan ranges

» is insensitive to ambient light and temperature fluctuations

» is not restricted to one type of inserts but usable for various forms and sizes

» measures without manual user influence

» achieves measurements in approx. 20 seconds

» offers miscellaneous export and print options

» measures large bevel length

» offers easy handling with a special coarse drive that simplifies focusing on the insert

The InfiniteFocus standard system covers ameasurement area of 10cm x 10cm. For themeasurement of larger measurement fields,special solutions are available. The IF-XLargeseries offer high resolution 3D measurementcapabilities on larger and heavier componentswith the same accuracy and repeatability as thestandard system.

The IF-Sensor provides even in a harsh production en-vironment high resolution measurements across largemeasurement areas. The sensor is temperature stableand insensitive to vibration.

Amongst other parameters, the IF EdgeMaster measures edge radius andbasket arch form.

MEASUREMENTMODULES

Separate measurement modules provide the tools for complete surface measurement.

For all measurement modules, InfiniteFocus provides an in-depth definition of the geo-metrys´ coordinate system. In addition, a variety of form removal utilities is available forprofessional form and roughness measurement. This allows a simple, accurate and re-peatable surface measurement on complex components. All measurement modules areeasy and intuitive to use throughout the well prepared graphical visualization and severalexport functionalities.

ISO 25178 - 6

VDI/VDE 2617- 6.2

ISO 4287

ISO 4288

ISO 11562

ISO 5436 - 1

ISO/TS 16610 - 1

ISO/TS 16610 - 20

FOLLOW THE STANDARDS. THE INFINITEFOCUS MEASUREMENT RESULTSGO CONFORM TO THE FOLLOWING STANDARDS (AS OF SPRING, 2010)

ISO 25178 - 2

ISO 13565 - 2

ASME B46.1

ISO/TS 12180 - 1

ISO/TS 12180 - 2

ISO/TS 12181 - 1

ISO/TS 12181 - 2

36 alicona I Measurement modules

FORM MEASUREMENT OFA PROFILEForm measurement along a user defined profile.Measure radii, angles, height steps and nor-mal distances manually or automatically.

ROUGHNESS MEASUREMENTClassic roughness measurements conforming to EN ISO 4287, 4288.The roughness is measured with comprehen-sive parameter evaluation of roughness, wavi-ness and frequency. Statistical evaluationsand the bearing ratio curve or spectral analy-sis are graphically visualized.

MEASUREMENT OF SURFACE TEXTUREMeasurement conforming toEN ISO 25178.Measurement of several common surface pa-rameters including statistical evaluation of be-aring area curve, fractal dimension,autocorrelation, gradient distribution, local ho-mogeneity and spectral distribution.

MEASUREMENT OF VOLUMEQuantification of pits or peaks.The volume is measured according to a userdefined border. The extensive positioning ofcutting layers or cutting surfaces provide auniversal tool.

2D IMAGE MEASUREMENTEvaluation of 2D-geometries.In the 2D-view of the measured surface fea-tures such as circles, straight lines, angles,parallel lines, distances, ellipses, rectanglesetc. can be measured.

AUTOMATIONProgrammable solution for repeatingmeasurement tasks.Several InfiniteFocus measurement applicati-ons are programmable, from a simple profileform measurement to more complex hard-ware control.

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STANDARD MEASUREMENTMODULES OFINFINITEFOCUS ARE:» Profile-Form measurement» Profile-Roughness measurement» Surface-Texture measurement» Volume measurement» 2D image measurement» Automation

Measurement modules I alicona 37

38 alicona I Precision

PROVABLYPRECISE AS A SWISS CLOCKWORK.We blindly trust in the precise timekeeping of a Swiss clock. In modern me-trology, precision needs to be proved. Proving the measurement accuracyis achieved by traceable international reference standards.

measurements, the supplier of optical3D measurement solutions has set amilestone in optical metrology.

Precision is not all.It must be traceable.The tactile measurement techniqueconforms to a number of establishedstandards that confirm the accuracyof the measurements made. Also,these standards make tactile measu-rements trustworthy. However, tactile measurement techni-ques are not comprehensive enoughfor the micro structured surfaces thatare produced nowadays, and, for op-

tical measurement devices, standardsfor proving the accuracy have beenmissing. Until recently there was no optionavailable that allows tracing back theaccuracy of an optical roughnessmeasurement to a certified standard,instead it was common practice touse standards from tactile devices.Alicona CEO Dr. Stefan Scherer aboutthis problematic practice: “Most stan-dards are designed only for tactilesampling. To trace back an opticalmeasurement by using a standardmade for the tactile instrument classis a rather questionable venture. Twoprocesses and techniques are mixed

up that should be obser-ved differently.” That isthe reason why Aliconahas taken care that thislack of appropriate stan-dards is now no longeran issue. With its speci-ally developed roughness

For a measurement to be trusted itmust be repeatable and traceable.Only comparison with internationalestablished standards as e.g. of thePhysikalisch Technische Bundesan-stalt in Braunschweig, Germany (PTB– which is the national metrology insti-tute providing scientific and technicalservices) or the National Physical La-boratory in Teddington, UK (NPL) cancertify the accuracy of a measurementresult. To be trusted, all measure-ments performed by InfiniteFocus aretraceable back to reference standardsby both institutions. Alicona has evengone further. By developing a trace-able standard for optical roughness

“The traceability of measurement results to a common and well known reference is an ab-solute essential factor. Otherwise no significant comparison with other measured values,certified standards or well known thresholds or target values can be achieved. With outthe traceability no binding statement can be made about the matching of two com-ponents.”

Prof. Richard Leach, Principal Research Scientist, NPL

Precision I alicona 39

“It is evident that Alicona is very actively involved in working out new standardsand guidelines.”

Dr. Ulrich Neuschaefer-Rube from the Coordinate Metrology Department of the PTB

The Alicona roughness standard is appropriate for all optical ISO-certified

measurement technologies.

Prof. Dr. Jörg Seewig is head of the In-stitute for Measurement and Sensor-Technology at the Technical UniversityKaiserslautern, Germany. Here the ex-pert and author of various publicationsexpresses his views about the statusquo of optical measurement in pro duc-tion.

“SOME TASKS CANNOT BE SOLVED BYTACTILE MEASUREMENT ANYMORE.”It is a paradox: On one hand physical limits are being rea-ched by tactile measurement systems.On the other hand, optical systems, thathave not reached their limits, have notbeen widely taken up in integrated pro-duction measurement and quality assu-rance.Why is this? It is a fact that modern fine detailedfunctional geometries have become toocomplex to be measured with a tactile sy-stem. The results are simply not robustenough and vary depending on the mea-surement position. Applications in the automo-tive sector, such as the mea-surement of cylinder walls,shafts and seals, typify theproblem. A tactile system,for example, would damagea seal and would neitherprovide characterization dataon a granular surface norfunctional data on a honedsurface. These measure-ment tasks can only beachieved by optical me-thods. More and more ma-nufacturers recognize thepossibilities provided by op-tical measurement techni-ques and have started to use thesetechniques for quality assurance. How -ever, this is still more valid in the labora-tory, rather than in production. But why is it that optical measurementhas been rarely used in a production nearenvironment even though there is an in-creasing need to do so? Surprisingly, thisis not a result of missing or not fully deve-loped products or solutions; it is the resultof inadequate strategies and standards tosatisfy the users.

Prof. Dr. Jörg Seewig

Continued on page 40

GUEST COMMENT

standard, which is traceable to thePTB, Alicona provides a standard forthe whole branch. For the first time,there is a standard available that isappropriate for all optical ISO certifiedmeasurement techniques.Prof. Jörg Seewig from the Institute ofMeasurement and Sensor-Technologyat the Technical University Kaiserslau-tern, Germany sees that one of themost fundamental requirements forscience and industry is fulfilled: “Thisnew standard 100% fits to the needsof the optical measurement branch.With this standard Alicona has set anew milestone.”

“The optical measurementtechnique requires inter-nationally valid standardsand guidelines!”With this standard, both industry andscience, see one of their major re-quests fulfilled as it will boost the ge-neral acceptance and furtherdevelopment of optical measurementtechniques. However, there still is alot to be done: “Tactile measure-

ments are trusted, as not only stan-dards and guidelines are available,but also approved material standards.For optical measurements this trust-worthiness is still missing, because atpresent only a few standards and gui-delines exist and particularly often noappropriate material standards areavailable. This is one of the reasonswhy the user often cannot judge if thechosen system is the correct option forhis application”, concludes Dr. UlrichNeuschaefer-Rube from the Coordi-nate Metrology Department of thePTB. Since its foundation Alicona hasbeen active in several important com-mittees, commissions as well as inthe ISO-federation. As a main drivingforce, the company essentially contri-butes to a worldwide positioning ofoptical measurement and increasesits development and acceptance.

40 alicona I Precision

Tactile systems are well established andhave a wide range of standards and refer -ence tools making the methods comfortableto use with traceable results. But with opticalmeasurement, efforts have not been com-pleted to help the user decide which set-tings or parameters can be used to achieveoptimal measurements.For tactile instruments a number of stan-dards and reference tools are available toverify the accuracy of measurement results,these standards are still needed in the worldof optical instruments. Most companieshave only focused on the development oftheir products, leaving out further aspects ofproviding usability such as guide lines andstandardization. Only a few visionary forcesfrom industry are looking beyond their tech-nical horizons to counteract this drawback. Thanks to them necessary standardization isslowly but surely being reviewed in inter -national committees. With EN ISO 25178first steps have been made. Hopefully thesedriving forces keep going and ensure that innear future optical measurement techniqueswill also find its true place in production.

ADD ONS

CALIBRATION-TOOLStandard, traceable to the PTB,for verifying the vertical and lateralaccuracy of InfiniteFocus. It pro-vides a height step (1000µm) forthe vertical check and variouschess patterns for the verifica-tion of lateral results.

ROUGHNESS-STANDARD-500Roughness standard for opticaland tactile measurements tra-ceable to the PTB. With this toolthe accuracy of opticalroughness measurements is ve-rified. All ISO certified opticalmeasurement techniques arevalidated.

ADVANCED-INSERT-GRIPGrip for the measurement of small ob-jects in variable oblique positions. Thisgrip can be adjusted to most speci-mens and also locked in the desiredposition. Measurement comfort and re-peatability are increased.

INSERT-GRIPA tool for placing small components inan exact 45° position. This minimizessources of error and increases repe-atability.

“Thanks to some visionary driving forces the necessary standardization is being created. This will make optical measurement accepted both in production and integrated quality assurance.”

Prof. Dr. Jörg Seewig Institute for Measurement and Sensor-Technology at the

Technical University Kaiserslautern, Germany.

Guest comment continued

Precision I alicona 41

ADD ONS

RING LIGHTAdditional light source for impro-ved illumination. Especially usefulon very complex surfaces enab-ling measurements in more detail.

POLARISATIONOption for filtering out reflecti-ons. Allows the measurement ofsurfaces with varying reflectiveproperties and steep flanks.

ROTATION-TABLEA rotation table for aligning com-ponents along x- or y-axis of thesystem. Ideal for the measure-ment of horizontal or verticalgrooves and small ImageFields. Atime saving device.

ROTATION-GRIPClamping device, for horizontal moun-ting of components such as drills ormilling cutters enabling it to be rotatedinto the desired position. Also cuttingedges are measured easily.

REAL3D-ROTATION-UNITAdd-on for the automatic rotation ofspecimens for up to 360° measure-ment. When used in combination withthe various measurement modules,Real3D allows surface measurementsfrom every perspective. With only onemeasurement the complete 3D datasetis available.

VERIFICATION-TOOLStandard, traceable to the PTB, withmiscellaneous form artifacts such assteep slopes, angles and cylindersizes. Used for verifying the accuracyof form measurements.

CLAMPING-SETA set of different clamping bars formounting and securing specimens in acertain position: A flexible solution forflat, steep and round components.

42 alicona I Technology

InfiniteFocus is based on the principle of Focus-Variation; a stable technology with

high measurement point density and an inclusive measurement uncertainty matrix

for lab and production.

”The optical measurement techniquestill has to face many challenges. Ho-wever, Focus-Variation fulfills some ofthem already today. The measurementtechnique by Alicona achieves for ex-ample high resolution measurementsin high speed. Most characteristic is thecombination of a micro coordinatemeasurement system with the optionfor area based measurements.”

Prof. Richard Leach,Principal Research Scientist, NPL

The specimen is placed onto the stage and isilluminated with modulated light. This light istransmitted through the optic and focusedthrough a beam splitter onto the specimen.Coaxial illumination is created.

The light is reflected by the specimen and pro-jected on to a digital sensor in the precisionoptic. Depending on the objective selected va-rious lateral and vertical resolutions can beachieved.

“A MEASUREMENT VALUEWITHOUT A MEASURE-MENT UNCERTAINTY ISUSELESS!”

Dr. Ulrich Neuschaefer-Rube, PTB

““TThhee mmeeaassuurreemmeenntt uunncceerrttaaiinnttyy iiss aann eess--sseennttiiaall ppaarrtt ooff aannyy mmeeaassuurreemmeenntt vvaalluuee..TThhiiss iiss wwhhyy FFooccuuss--VVaarriiaattiioonn pprroovviiddeess iinn--ffoorrmmaattiioonn ooff tthhee rreeppeeaattaabbiilliittyy ooff eevveerryyssiinnggllee 33DD--ppooiinntt.. TThheerreeffoorree tthhee uusseerr ggeettssaann eessttiimmaatteedd mmeeaassuurreemmeenntt uunncceerrttaaiinnttyywwiitthh eevveerryy mmeeaassuurreemmeenntt vvaalluuee.. DDrr..UUllrriicchh NNeeuusscchhaaeeffeerr--RRuubbee ffrroomm tthhee PPTTBB::““II ddoo nnoott kknnooww ooff aannyy ootthheerr tteecchhnnoollooggyytthhaatt ddeelliivveerrss aatt tthhiiss ttiimmee iinnffoorrmmaattiioonnttoo vveerriiffyy tthhee qquuaalliittyy ooff aa mmeeaassuurree--mmeenntt vvaalluuee aass iitt iiss aacchhiieevveedd bbyyFFooccuuss--VVaarriiaattiioonn..““

InfiniteFocus provides high resolution and re-producible measurement results in the lab andin rougher manufacturing environments.

» The technology works reliably and is not affected by environmental influences such as temperature or ambient light. This is dueto the large amount of data that is used for measuring every single z-value.

» InfiniteFocus is a high quality measurementdevice and generally insensitive to external influences. The system includes a vibration absorption construction and is therefore vibration resistant.

» Various light sources minimize the impact of light.

» InfiniteFocus delivers an estimation of the measurement uncertainty for every 3D-point.

THE TECHNOLOGY: FOCUS-VARIATION

HHooww FFooccuuss--VVaarriiaattiioonn wwoorrkkss

Technology I alicona 43

SSCCIIEENNCCEE && PPRRAACCTTIICCEE IINNDDIIAALLOOGGUUEE:: WWHHAATT IISS AA““SSTTAABBLLEE”” MMEEAASSUURREEMMEENNTTDDEEVVIICCEE??

Prof. Dr. Jörg Seewigis chair person of the Institute for Mea-surement and Sensor-Technology at theTechnical University Kaiserslautern,Germany.HHee iiss ccoonnvviinncceedd tthhaatt aa ““ssttaabbllee mmeeaassuu--rreemmeenntt ssyysstteemm”” mmuusstt ……

» fulfill technical specifications that guaranteethat the measurement task can be solved

» support intuitive and easy to use interfaces

» deliver unambiguous, precise and significant results that do not allow any space for interpretation

» offer information about measurement uncertainty (a so called measurement uncertainty matrix) for every measurement value

» provide results that are traceable back to certified standards (NPL, PTB…)

As the distance between specimen and objec-tive is varied the change of sharpness is mea-sured. Depending on the 3-dimensionalstructure of the specimen some areas are de-picted sharp or not, the sharp data is used toconstruct the 3D dataset.

Essential to the measurement result is the cor-rect interaction of modulated illumination withcontinuous vertical movement and the quality ofthe sensor measurement. This process is achie-ved with the SmartFlash technology developedby Alicona.

For every position on the object the sharp regi-ons are measured. The variation of the sharp-ness values is used for the measurement of the3D-postion. This is how dense 3D-datasets arecreated.

MEASUREMENT POINT DENSITY AND REPEATABILITY

A large number of dense measurementpoints, also on larger areas, provideshighly repeatable measurements. Alicona also automatically provides anestimation of the repeatability of everysingle measurement value analyzingthe variance of each measurementpoint in the z-direction. This repeatability measure helps toevaluate the quality of individual mea-surement points. This again allowsmeasurement results that are easy tointerpret. In addition it shows if and towhich extend vibrations occurred du-ring the measurement.

IINNFFIINNIITTEEFFOOCCUUSS::

Dr. Manfred Prantl, Alicona, CEO for Research and Development“Security and reliability are the cornerstones ineach development. We develop with high in-vestment in R&D, ensuring that we can tacklethe needs required in industry and science.

» our technical specifications guarantee versatility and precision

» the use of InfiniteFocus is easy to understand even though it allows a variety of different settings

» InfiniteFocus delivers unambiguous results including information about the measurement uncertainty of every 3D-point

» all measurement results are traceable back to the PTB as well as to NPL. Additionally we have developed our own standard that allows the verification of the accuracy of optical roughness measurements”

THE TECHNOLOGY: FOCUS-VARIATION

44 alicona I Specifications

TECHNICAL SPECIFICATIONS

Measurement principle non-contact, optical, 3 dimensional, based on Focus-Variation

Measurement result2-100mio 3D points in registered true color information (maximum is dependent on the used measurement module)

Maintenance maintenance free

Illumination white LED coaxial light, high power, controllable; Optional: white LED ring light, controllable, polarization

Nosepiece 6 objectives manual or motorized

Travel range X:100mm, Y:100mm, Z:100mm

Weight 95-100kg, depending on equipment

Size measurement system WxDxH 710mm x 540mm x 628mm (up to 868mm)

Temperature range possible: 5° - 40°C, calibrated for: 18° - 22°C (other temperature ranges can be calibrated)

Temperature gradient less than 1° per hour

Power supply 900W;110-230V~; 50-60Hz

Size ControlUnit WxDxH 540mm x 682mm x 360mm

Specimen surface texture surface topography Ra above 10-15nm with a Lc of 2µm, surface structure dependent

Max. height of specimen 100mm up to 240mm

Max. weight of specimen 35kg, more on inquiry

Maximum slope angle up to 85°

Sample preparation none

Objectives 2,5x 5x 10x 20x 50x 100x

Lateral sampling distance µm 3.52 1.76 0.88 0.44 0.18 0.09

Min. lateral resolution µm 58.71 23.48 11.74 8.8 6.4 4.4Max. lateral resolution µm 6.92 3.49 1.75 0.88 0.64 0.44

Min. repeatability (vert.) µm 0.8 0.12 0.03 0.015 0.008 0.003

Max. scan height (approx.) mm 8 22 16 12 9 3.2

Scan speed* µm/s 2300 400 100 50 20 10

Best vertical resolution** nm 2300 410 100 50 20 10

Vertical dynamic 3400 52000 160000 250000 430000 380000

Working distance mm 8.8 23.5 17.5 13.0 10.1 3.5

Field of view X µm 5716 2858 1429 715 286 143

Field of view Y µm 4351 2175 1088 544 218 109

Max. extended field of view Y mm² 10000 10000 10000 4500 700 150

Max. uni-directional scan extension mm 100 100 100 100 100 100

Measurement modules and utilities

Standard: ProfileFormMeasurement (height, angle…), ProfileRoughnessMeasurement (Ra…), SurfaceTextureMeasurement (Sa, fractale dimension…), VolumeMeasurement, 3D-Editor, FormRemoval; Optional: 3DFormMeasurement, DifferenceMeasurement, ContourMeasurement, EdgeMeasurement;

Automation IF Automation (built-in script editor), .NET Remoting interface

Visualization 2D-image and high resolution 3D visualization

Database intuitive, graphical database

Import/Export Simple export to STL and VRML, import of CAD-data with STL format, QDAS export, variety of reporting functionalities

Available in German, English, Korean, Japanese

SOFTWARE

GENERAL SPECIFICATIONS

SPECIMEN

OBJECTIVES

*) The maximum scan speed is not achieved by every application.**) Vertical resolution can be adjusted depending on the application, this also influences the scan speed.

Specifications I alicona 45

(1) Sensor head and stiffened sensor ribs (2) passive vibration damping and x-/y-stage (3) manual nosepiece (4) motorized nosepiece (5) 2.5x, 5x, 10x, 20x, 50x and 100x objective

(6) ring light (7) polarization disc for ring light (8) polarization for coaxial light source (9) height extension* for larger specimens (10) ClampingSet (11) InsertGrip (12) AdvancedIn-

sertGrip (13) RotationTable (14) RotationGrip (15) Real3DRotationUnit

*) can only be changed by certified Alicona service engineers

Objectives 2,5x 5x 10x 20x 50x 100x

Min. measurable height nm 2300 410 100 50 20 10

Max. measurable height (approx.) mm 8 22 16 12 9 3.2

Step height accuracy (1mm height step) % - 0.05 0.05 0.05 0.05 0.05

Max. measurable area mm² 10000 10000 10000 4500 700 150

Max. measurable profile length mm 100 100 100 100 100 100

Min. repeatability nm 800 120 30 15 8 3

Min. measurable roughness (Ra)* nm 7000 1200 300 150 60 30

Min. measurable roughness (Sa)* nm 3500 600 150 75 30 15

Min. measurable radius µm 20 10 8 5 2 1

Min. measurable vertical angle ° 20 20 20 20 20 20

RESOLUTION AND APPLICATION LIMITS

The entries in the table are traceable values.*) The minimum measurable values are dependent on the structure of the specimen.

46 alicona

MEASUREMENT WITH INFINITEFOCUS

Bildquelle: Prof. Jan Aurich, Fertigungstechnik und Betriebsorganisation, Technische Universität Kaiserslautern

alicona 47

Bass Ceratizit EDM ETH

NFIInspireFZGFette

NPL oerlikon PTB PTS

Universitätsklinikum Tübingen

TU Kaiserlautern

This is a selection of InfiniteFocus user who have contributed to the first issue of FOCUSvariation

TU Hamburg Harburg

G4-20102011

Technical data, images, descriptions without obligation. We reserve the right to modify content.®alicona and ®InfiniteFocus are registered trademarks, ©Copyright by Alicona

Alicona GermanyAlicona GmbHBuchenötz 2

83471 SchönauGermany

Tel: +49 8652 6553901Fax: +49 8652 6553902

info@alicona.de

Alicona AsiaAlicona Korea Pacific Co. Ltd.104-1606, 16th Floor, Hang-

angno Byucksan Megatrium 2-8Hangangno 2-ga Yongsan-gu

140-780 SeoulSouth Korea

phone +82 2795 5045fax +82 2795 5044

sales.asia@alicona.com

Alicona USAlicona Corporation

1261 Humbracht CircleSuite G, Bartlett

IL 60103USA

phone 630 372 9900fax 630 372 9965

sales.us@alicona.com

Alicona FranceAlicona SARL

Rue de Savoie 1191940 Les Ulis

Francephone +33 169 86 9137fax +33 169 86 9137sales.fr@alicona.com

Germany NorthIngo Böhm

phone +49 175 2932223ingo.boehm@alicona.com

Alicona HeadquartersAlicona Imaging GmbH

Teslastraße 88074 Grambach/Graz

Austriaphone +43 316 4000 700fax +43 316 4000 711info@alicona.com

Alicona UKAlicona UK Ltd.Lime Tree House15 Lime Tree Walk

SevenoaksKent TN13 1YH

UKphone +44 1732 746262fax +44 1732 465500sales.uk@alicona.com

Germany South-WestDaniel Soares

phone +49 151 1214 3339daniel.soares@alicona.com

Germany South-EastMatthias Strößnerphone +49 151 23530254

matthias.stroessner@alicona.com