1. The Challenge
A leading automotive parts manufacturer based in Germany faced a recurring quality control bottleneck. Their high-precision engine components featured intricate internal cavities with complex geometries. Traditional measurement tools, such as calipers or CMM (Coordinate Measuring Machines), were unable to access these areas, making it impossible to verify internal dimensions, resulting in a production defect rate of 15%.
2. The Solution: Chemoment Metrology Silicone
The manufacturer introduced Metrology Silicone Replication Materials to implement a non-destructive testing workflow. This material was chosen for its specific technical advantages:
- Superior Flowability: Ensures complete penetration into complex micro-cavities.
- High Tear Strength: Guarantees integrity during extraction from complex shapes.
- High Replication Precision: Captures microscopic surface details to ensure data accuracy.
3. The Execution
The technical team used a static mixing nozzle to inject the silicone into the internal cavities. The material achieved full cure at room temperature within 5 minutes. After removal, the silicone replica was measured using optical or 3D scanning systems to verify dimensions.
4. The Results
By integrating this solution, the client achieved:
- Inspection Efficiency: Internal measurement time was reduced by 60%, eliminating the need for destructive testing.
- Precision: The replication accuracy reached 99.98% against CAD drawings.
- Quality Control: The client successfully reduced their defective rate from 15% to below 2%, significantly lowering annual waste costs.
"Chemoment's Metrology Silicone is our 'secret weapon' for measuring complex internal cavities. It is not only easy to operate, but the captured details allow us to precisely identify every minor machining deviation."
— Quality Assurance Manager, Automotive Manufacturing
Need a Precision Replication Solution?
Are you facing challenges with measuring complex shapes or surface defects? Contact us today for a free sample and one-on-one technical guidance.
