It’s ‘Metrology,’ NOT Meteorology: And Why It’s Nothing to Fear
Jim Cassady | Integrated Market Director | 3D Metrology | FARO® Technologies

The new Gage FaroArm® is ideal for small and medium sized businesses for performing high accuracy tasks.
From seasonal hurricanes and tornados, to blockbuster winter storms,
meteorology
can pack a punch. In fact, a recent study on just one thunderstorm over India estimated it contained 1.3
billion volts. It’s a shocking statistic that for many underscores a natural fear of the weather and even
the words associated with it. After all, meteorology contains the word meteor – as in de-orbiting giant
rock.
But there’s another word in the English language that sounds a lot like meteorology that also sends
shivers down peoples’ spines, but it shouldn’t: metrology. While they share most letters in common,
meteorology is the science of weather and climate while metrology is the science of measurement and
weights. And it is the science of measurement (and the tools associated with its applications) that small
and medium-sized businesses (SMBs) should be paying particular attention to – regardless of the weather.
In fact, metrology need not be scary at all. Nor should SMBs assume they require special skills or an
advanced mathematical degree to master the technology. Today, thanks to advanced and easy-to-use 3D
measurement hardware (such as portable measurement arms) and software, metrology has become an easy and
straightforward applied science. Especially when compared to accuracy challenged hand tools, bulky fixed
coordinate measuring machines (CMMs) and similar products, operators can measure anytime, anywhere,
including while the part is still on the machine producing it. Not only that, but businesses that adopt
such metrology solutions (and their clients) will benefit by having a permanent digital record of the
inspection report. Transparency and efficiency at its finest.
A Sunny Forecast for Portable 3D Measurement Arms
So, what is meant when referencing the metrology tools of today? For the purposes of
this article, they are the portable, digital tools intended for product build and verification. The small
and medium-sized industries where metrology comes into play are diverse and include: machine shops,
casting, forging, fabrication, tooling, and mold & die, manufacturing/machine assembly.
Tools like the FaroArm® are an excellent example of what transportable, digital measurement is
all about.
The new FARO® Gage, for instance, allows for confident 3D measurements across a wide range of
machine shop
and industrial applications. It is ideal for small size, high-accuracy tasks, and vastly improves upon
and replaces multiple hand tools like micrometers, calipers, and height gauges thanks to its convenience,
speed, and ease of use. With a product like the Gage, inspection bottlenecks are all but eliminated,
along
with operator variability – a factor that can make the difference between small business profitability or
loss.
In the case of the Gage, the collected data is stored directly on a computer and compared against the
original CAD data. CAD Data? Sure – your computer numeric control (CNC) machines are driven by
CAD data, so why not verify and measure using the same nominal data that is used for machining? No CAD
data, No worries? As long as you have a referenceable nominal measurement spec such as an old-fashioned
blueprint, you can still use these tools. All of this is a way to ensure that the part measured is
verified according to the original design specs. And it helps ensure that part rejects and scrap are
reduced to a minimum.
The Gage is but one example of how innovative and affordable 3D metrology tools can help a small or
medium-sized business punch above their weight. Another group of products are laser trackers. These are
best suited for large-scale 3D measurement. Laser trackers measure angles and distance. It really is as
simple as point and shoot and is ideal for assembly alignment, part and assembly inspection, machine
installation and alignment, and reverse engineering. For instance, instead of measuring each individual
part for a boat assembly by hand, laser trackers can measure entire hulls. As in the case with all
digital models, the measured specs can be compared to original design specifications, whether they are
CAD or blueprints.

In rounding out the 3D metrology hardware trifecta, there’s also the burgeoning
field of virtual templating which uses laser-guided assembly projection. These devices project a visible
laser outline onto 3D surfaces and objects which assemblers use to sequence work and position components.
Think of it like the paint by numbers approach to 3D metrology. All operators have to do is match the
part to the image outline and the assembly is complete.

CAD-based virtual templating eliminates the need for physical templates and
hard tooling, which like other digital solutions, reduces the risk of human error and costly rework. With
these tools, manufacturers can avoid the time and expense associated with using large, heavy templates
while significantly improving quality control.
Long Range Outlook: Steer Clear of Fear
For small and medium-sized businesses that have never worked with products like
these, some trepidation is natural. Many SMBs work with as few as 10 manual measurement tools and making
the jump to computer-based 3D measurement can feel daunting. But it shouldn’t.
One of the most common concerns is that the technology itself is too precise. That is to say that it
generates so much data that the information overload will frustrate staff. Or that it will show
alignments so slightly out of tolerance relative to the original design specs that it’s not worth
correcting the error. (Which goes the internal debate, why purchase a measurement tool in the first
place if all it does is tell me things I don’t need to know.)
But as any seasoned professional knows, ignorance is not bliss; it’s ignorance. 3D measurement isn’t
about upending your existing processes. Rather, tools like the Gage, laser trackers and virtual
templating, all help identify problems and errors further upstream in the manufacturing process. The
sooner an error can be detected, the less scrap, re-work and overtime costs are generated. For SMBs
with high throughput, alignment errors, even if it’s only a small percentage of your product output, can
become expensive fast. The smart application of 3D metrology allows manufacturers to avoid multiple
“profit killers”:
- Rework and scrap
- Putting additional manufacturing time and costs into parts that are out of tolerance and would not pass final inspection – perhaps the costliest example of scrap and rework.
- Shipping non-conforming products to customers which is not only costly, but the resulting customer dissatisfaction could lead to lost contracts and revenues.
So, is metrology scary? Not anymore. In fact, not embracing 3D metrology at all might
be what is really scary.
In the years ahead, as 3D metrology continues to advance into all aspects of manufacturing, a growing
number of SMBs will embrace this technology. And increasingly, 3D measurement tools will be integrated
into smart factory applications whereby even more data will be collected and acted upon. Adopting these
solutions now may be just the competitive differentiator your business has been looking for to stand out
from the crowd.
Now that’s a revenue and profitability boost that’ll be sure to “make it rain.”
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