Total Screening

Complete, contact-free, and non-destructive: 3D measurement using a computer tomograph generates a digital image of all internal and external structures. 1zu1scale uses this measurement method to provide a complete overview of complex, delicate, and precise components with integrated functions. Even reflective, transparent, and painted parts can be measured using CT.

Quality testing takes place immediately after production – whether in 3D printing or injection molding. The exaCT L150 industrial computed tomography scanner from Wenzel provides absolute quality assurance with an accuracy of up to five micrometers (5 μm = 0.005 mm) and nearly 4K resolution (3000 x 2500 pixels). A detailed measurement report for each batch eliminates the need for external measurement processes. This in turn accelerates the introduction of market-ready series components.

Fast, Precise, Multifunctional

Depending on the shape and size—from elements the size of a fingernail to models the size of the palm of your hand—the measurement process takes an average of thirty minutes. In addition to the geometric inspection of dimensional accuracy, any material inclusions and impurities as well as production-related warping and shrinkage of the material can be checked. The color comparison of 3D scans and 3D data illustrates any deviations from the target value.

A precise Part alone is not enough

Both 3D printing and injection molding require consistently high quality and repeatability. That is why 1zu1 monitors the process by taking a defined number of measurements of components in a batch. The exaCT L150 also enables individual measurements such as form and position tolerance, parallelism, coaxiality, distances, or cuts, as well as assembly analyses. The system also allows multiple measurements of up to 20 parts.

Time Savings and Quality Assurance

The process pays off in practice. With the ViroTrack blood analysis plug-in module from BluSense, the sensitive microfluidics of the injection-molded parts could be checked immediately after production. This saved time and enabled rapid and flexible optimizations. Precise data analysis is also useful in the opposite direction, as demonstrated by the example of the Fliphead multi-purpose mouthpiece. Here, the perfectly sounding 3D-printed prototype was examined. The findings were directly incorporated into the design of the series component.

Since 2022, injection molded parts manufactured by 1zu1 have been sent through a CT scan after a predefined number of pieces have been produced. This enables us at 1zu1 to guarantee the quality of our components in terms of dimensional requirements on a sustainable basis.

In addition, our ongoing quality assurance is carried out using CT technology. This means that we continuously check the accuracy drift of our 3D printing technology by performing recurring tests, always using the same data sets.

Tested Quality at a Glance

• Complete, high-resolution (3000 x 2500 pixels) 3D image of the object
• Accuracy: from 5 µm
• Problem-free measurement of transparent and reflective parts
• Measurement of micro parts and components with a size of up to 150 x 300 millimeters
• Testing of dimensional accuracy, material inclusions, contamination, material distortion, and shrinkage
• Customer-friendly presentation of the evaluation
• Process monitoring thanks to quality verification for each batch
• Assembly analyses possible through multiple measurements of up to 20 parts