Aim

Fast and accurate fixture to enable the measurement of a pre-production series of a front and rear bumper. The bumpers were already fully assembled and painted.
The fixture needed to simulate the car body which the bumper would be fastened to, therefore the real guiderails had to be mounted to the fixture.

Solution

• Contact points were designed very quickly and directly in STL-format ready for 3D printing using RapidFit software. Each RapidFit fixture represents a contact area of the car between the bumper parts and the body.
• Contact points were built using the additive selective laser sintering technology.
• Contact points were certified using a 3D optical measuring device.
• AluQuick beam structure was assembled and the RapidFit contact points were fixed to the 3D adjustment blocks. The contact points can be adjusted from 0.5mm up to 0.1mm according the required specifications with our mobile CMM device. As a result of the flexibility of the adjustment blocks, it is even possible to adjust the guiderails to zero position to avoid influence of dimensional deviation of the guiderails during measurement of the bumper.

Fast design

With our software the contact points are designed very quickly and directly in STL-format ready for 3D printing. If there are design changes during the process, only the RapidFit parts need to be redesigned.

After building, usually using selective laser sintering technologies, all contact points are certified using a 3D optical measuring device.

In-house validation of fixture

After certification, the AluQuick beam structure is assembled and the RapidFit contact points are fixed to the 3D adjustment blocks. The contact points can be adjusted from 0.5mm up to 0.1mm according the required specifications with our mobile CMM device.
Because of the flexibility of the adjustment blocks it is even possible to adjust the guiderails to zero position to avoid influence of dimensional deviation of the guiderails during measurement of the bumper.

Value adding through 3D optical measuring

Using photogrammetry and 3D scanning we are able to efficiently perform typical automotive measurements e.g. Gap & Flush analysis, using RPS alignment and even make a full 3D colour map of the part with an overall accuracy of 20μ.

Qualified partner

The aluminum beam structure of this fixture is manufactured by our partner company, founded in 1969, and specialised in modular fixturing systems. For this fixture, the new AluQuick beams are used because of its high flexibility and lower cost compared to AluFix.