Benefits of CT Technology
Overview
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Computed Tomography in the Plastics Industry

  • CTs work without destroying the workpiece
  • Nothing is hidden from CTs, components can be captured completely
  • CTs work quickly, a single scan provides holistic information on selected characteristics
  • CTs capture data in 3D, exceeding ultrasound or 2D X-ray scans
     
Computed Tomography in the Plastics Industry
ZEISS Reverse Engineering

Tool correction using ZEISS REVERSE ENGINEERING

Example: housing for a tank venting valve

Due to the difficulty in predicting the quality of an injection mold process, tools must often be reworked multiple times until the molded parts meet the quality requirements. With ZEISS REVERSE ENGINEERING software, the CAD model of the injection molding tool can be corrected using the nominal data of a plastic component and the actual-data generated using the ZEISS METROTOM. The software corrects defective component segments in the tool data set and ensures that the selected segments fit appropriately.

Only the area marked in blue is considered for tool correction because this is decisive for fit accuracy.
Only the area marked in blue is considered for tool correction because this is decisive for fit accuracy.
Color-coded nominal/actual comparison of the selected sub-area.
Color-coded nominal/actual comparison of the selected sub-area.
The nominal data of the product (yellow), the current tool shape (green) and the areas which must be corrected (white) in one display .
The nominal data of the product (yellow), the current tool shape (green) and the areas which must be corrected (white) in one display .

Assembly inspection in product development

Example: fit accuracy of a plastic screw-cap

With a ZEISS METROTOM CT system, it is possible to examine the quality and function of the cap in its original, screwed-on condition without cutting apart the bottle. Using the CT data obtained, the cap can be cross sectioned anywhere on the computer using ZEISS NEO insights software so that the analysis is as complete as possible. A freely rotatable, semi-transparent 3D view facilitates orientation and interpretation.

The CT data display using ZEISS NEO insights software shows if the seal is properly positioned on the bottle.
The CT data display using ZEISS NEO insights software shows if the seal is properly positioned on the bottle.
Different material densities are used for the color display of the bottle and cap.
Different material densities are used for the color display of the bottle and cap.
The CCT data display using ZEISS NEO insights software shows if the seal is properly positioned on the bottle.

Random sampling for statistical process control

Example: button for a seat belt buckle

Example: button for a seat belt buckle

The button on a seat belt buckle in the car must meet high quality standards to ensure that this safety-relevant component works faultlessly. Regular random sampling guarantees the quality of the production process because, of financial and technical reasons, it is not possible to inspect every seat belt button. With a ZEISS METROTOM computer tomograph, all dimensions to be captured within the scope of process control can be inspected with just a single scan. It is even possible to insert multiple components into the CT system at once and inspect them.

Best fit of CT data (blue) and CAD data (gray). Measuring values outside tolerance are marked in red.
Best fit of CT data (blue) and CAD data (gray). Measuring values outside tolerance are marked in red.
Detail analysis of a curve form on the component using ZEISS CALYPSO CT
Detail analysis of a curve form on the component using ZEISS CALYPSO CT
Inspection of pores
Inspection of pores
ZEISS CT Solutions - From Lab to Production

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