In automotive manufacturing, Body-in-White (BIW) inspection is a critical step that ensures every component fits seamlessly during final assembly. Even the smallest deviation in the sheet metal structure can impact doors, engines, and glazing systems, making precision essential.
Traditionally, BIW inspection relied on manual gauging and conventional measurement methods. While effective, these approaches were time-consuming, prone to operator variation, and often created bottlenecks in production. Today, advanced metrology solutions like Hexagon’s Absolute Tracker AT960 with AS1 scanner are redefining this process.
In a recent implementation, a leading automotive manufacturer transitioned from manual inspection to a digital workflow using the AT960. Instead of capturing limited measurement points, the system scans millions of data points within minutes, creating a high-resolution digital twin of the BIW. This data is instantly compared with CAD models, generating intuitive colour maps that highlight deviations in real time.
The impact was immediate—inspection time reduced from nearly two days to just 3–4 hours, while results became consistent and repeatable, independent of the operator. With digital traceability and readiness for automation, the AT960 is helping transform BIW inspection into a faster, smarter, and more connected process.
Written by: Rupesh Thakur, Sr. General Manager – Division Portable Metrology