In automated production processes, the exact measurement of material thickness is an important specification for optimizing material usage, safety and product quality. Thickness measurement is a decisive factor in measurement technology for precisely determining the material thickness of components, semi-finished products or materials in industrial production and quality assurance.
Thickness measurement
Thickness measurement is the determination of the material thickness of an object at defined points or over an entire surface. Depending on the area of application, different measuring methods can be used, for example optical, mechanical or non-destructive methods. In industrial production, precise, reproducible results and a high measuring speed are of central importance in order to comply with quality standards.
In economic terms, thickness measurement serves to optimize material usage and minimize waste. Technically, it ensures compliance with tight tolerances and guarantees the function of safety-relevant components, for example in the automotive or aviation industry.
Thickness measurement should not be confused with coating thickness measurement. While thickness measurement determines the overall thickness of a body, coating thickness measurement concentrates on determining individual applied layers – such as paints, coatings, electroplating or films.
Metals, plastics, composites, etc.
The functionality of thickness measurement is based on various physical principles that make it possible to measure material thickness accurately and reliably. Depending on the requirements, material and area of application, different measuring systems and technologies are used, which can be integrated into industrial processes both manually and automatically.
The physical principles of thickness measurement range from mechanical contact and optical methods to ultrasound or X-ray measurements
Different physical processes are used depending on the requirements and material:
Modern laser triangulation sensors deliver precise measurement results even with rough and high-gloss surfaces, changing environmental conditions and high production speeds. Specialized 3D measuring systems offer additional advantages by capturing not only individual measuring points, but complete surfaces in three dimensions. This allows complex geometries or variable material thicknesses to be checked and documented efficiently.
An important aspect of all methods is the calibration of the measuring system in order to obtain reproducible and comparable results. Depending on the material and surface, physical properties such as reflectivity, temperature or surface structure must be taken into account in order to avoid measurement errors.
Typically, two sensors are positioned opposite each other to simultaneously measure the distance to the top and bottom. The difference gives the thickness. Alternatively, single-sided measurement methods with double reflection are used for transparent media.
Modern sensors can be integrated into control systems (e.g. PLCs) and provide data that can be processed in real time. Data evaluation is usually automated and can be visualized, documented and analysed using appropriate software solutions. This makes it possible to identify trends, monitor quality standards and realize continuous improvements in the production process.
QuellTech relies on high-precision laser triangulation sensors from the Q5 and Q6 series for thickness measurement. The systems are modular, low-maintenance and optimized for industrial series production.
Two opposing sensors synchronously detect the distance to the respective surface. The integrated software calculates the material thickness in real time – even with moving objects. Vibrations are eliminated by calculating the difference.
Quality assurance benefits significantly from precise and seamless thickness measurement with QuellTech laser sensor solutions. Defective production parts can be detected at an early stage, corrective measures can be initiated immediately and the traceability of all production steps can be ensured.
Measurement even with hot or sensitive materials.
Ideal for tolerance ranges <10 µm.
Avoid rejects by intervening immediately.
Suitable for metals, plastics, rubber, wood and all non-transparent materials.
Sensors withstand heat, dirt, oil mist, vibrations and ambient light.
Integration into digital manufacturing platforms, data analysis, predictive maintenance.
In the past, we have used QuellTech solutions for thickness measurement in a wide range of projects. Here is a brief selection of these projects:
In rolling or drawing processes, QuellTech Q6 sensors continuously measure the thickness of metal strips cold or up to 1000° C. The precise real-time measurement minimizes material usage and optimizes downstream processes.
When calendering rubber sheets, the sensors in the Q5 series detect the material thickness even during oscillating movements. The robust sensor technology provides reliable data even in vibrating machine environments.
Whether body panels, plastic cladding or foams – the thickness measurement systems are flexibly integrated into production cells. The thickness of adhesive beads is also measured. Automatic testing is carried out inline and documents compliance with all tolerances in accordance with IATF 16949.
QuellTech laser sensors are used for thickness measurement in the manufacture of metal parts and machine components.
The integration of advanced laser measurement technology into your machines can significantly increase production accuracy and efficiency. QuellTech specializes in OEM laser scanner integration solutions that are specifically tailored to the requirements of machine and plant manufacturers. Our customizable 2D/3D laser scanners can be seamlessly integrated into existing systems, enabling non-contact real-time monitoring and quality control.
The QuellTech Q6 laser scanner product series is particularly suitable for precise coating thickness measurements and thickness measurements at low coating thicknesses that require high Z-resolution and tolerance. The high travel speed of the Q6 laser scanners also enables successful use in inline production processes.
Further information: Q6 Laser Scanner
The QuellTech Q6 laser scanner product series is particularly suitable for precise coating thickness measurements and thickness measurements at low coating thicknesses that require high Z-resolution and tolerance. The high travel speed of the Q6 laser scanners also enables successful use in inline production processes.
Further information: Q6 Laser Scanner
QuellTech Laser Scanner Q4-80s with small form factor (86 x 44 x 25 mm) for robotic welding
QuellTech Laser Scanner Q4-60 with optional cooler and protective window system
We are happy to help you with that!
Stefan Ringwald
Technical Contact
If you have any questions about Volume Measurement or would like a consultation from QuellTech on this subject, we will be happy to help.
We would like to help you to precisely evaluate your specific measurement task. Through an initial free test measurement of your application, we can give you an early assessment of the feasibility.
There is always potential for improvement, we will help you with that. Contact us for more information or to make an appointment for a consultation.
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Your technically competent contact, Stefan Ringwald, will be happy to help you.
Our aim is to fully understand your specific technical requirements for your current measurement task.
Thanks to many years of experience with complex tasks in the field of 3D laser measurement, you will receive well-founded solution proposals from us.
