Hexagon Metrology ActiveScan Portable Blue-Light 3D Scanner

Overview

The Hexagon Metrology ActiveScan is a portable, high-precision blue-light structured light 3D scanner engineered for industrial metrology applications requiring rapid, non-contact surface digitization with traceable geometric fidelity. Unlike laser-based triangulation systems, the ActiveScan employs narrow-band blue LED illumination coupled with dual high-resolution CMOS cameras to project and capture fringe patterns across object surfaces. This principle—based on phase-shifting and stereo photogrammetry—enables sub-0.03 mm volumetric accuracy (as verified per ISO 10360-8 Annex D for volumetric performance testing) while minimizing sensitivity to ambient light and surface reflectivity variations. Designed for integration into production floors, quality labs, and field service environments, the system delivers calibrated point cloud data directly traceable to SI units through factory-applied NIST-traceable calibration certificates. Its modular architecture supports both handheld operation and tripod-mounted configurations, making it suitable for in-situ inspection of large assemblies as well as benchtop scanning of small precision components.

Key Features

• Portable form factor (<2.5 kg total system weight) with ergonomic handheld design and integrated thermal stabilization for consistent performance across ambient temperatures from 10 °C to 35 °C
• Interchangeable optical modules—including standard (0.1–1.0 m working distance), wide-field (up to 1.5 m), and high-resolution (sub-0.02 mm local resolution at 0.3 m)—enabling scalable measurement coverage without hardware replacement
• Real-time mesh generation and deviation analysis via onboard GPU-accelerated processing, reducing post-scan computation time by up to 40% compared to CPU-only workflows
• Ruggedized aluminum-magnesium alloy housing rated IP53 for dust and splash resistance, validated under MIL-STD-810G shock and vibration profiles
• Integrated reference target detection and automatic scale alignment, supporting seamless hybrid operation with Hexagon’s Leica Absolute Tracker AT960 or photogrammetry systems such as Leica Nova MS50

Sample Compatibility & Compliance

The ActiveScan reliably captures geometry from matte, semi-gloss, and lightly textured surfaces—including machined metals, injection-molded thermoplastics, die-cast aluminum, sheet metal stampings, and composite laminates—without mandatory surface preparation. For highly reflective or transparent parts, optional matte spray (certified per ASTM D2622 for residue-free removal) may be applied. All hardware and firmware comply with EU Machinery Directive 2006/42/EC, Electromagnetic Compatibility Directive 2014/30/EU, and RoHS 2011/65/EU. Calibration protocols adhere to ISO/IEC 17025 requirements when performed by Hexagon-certified service centers; full audit trails—including environmental conditions, operator ID, and equipment serial numbers—are retained for GLP/GMP-regulated environments.

Software & Data Management

ActiveScan operates natively with Hexagon’s Metrology Suite (v2024.1+), providing direct export to industry-standard formats including .STL, .PLY, .OBJ, and metrology-specific .IGES and .STEP AP242. The software embeds ISO 1101-compliant GD&T evaluation tools, automated report generation (PDF/HTML/XLSX), and version-controlled project archives compliant with FDA 21 CFR Part 11 electronic record requirements—including electronic signatures, audit logs, and user access controls. Integration with PolyWorks® Inspector and Geomagic Control X™ is certified via Hexagon’s Open Interface Protocol (HIP), enabling bidirectional CAD comparison, statistical process control (SPC) charting, and FAI reporting aligned with AS9102 and PPAP Level 3 standards.

Applications

• Aerospace: First-article inspection of turbine blades, wing ribs, and composite fuselage sections; reverse engineering of legacy tooling where CAD is unavailable
• Automotive: Dimensional validation of Class-A body panels, die-cast engine blocks, and EV battery enclosure assemblies; weld gap and flush analysis per VDA 6.3
• Electronics: PCB warpage measurement, connector pin coplanarity assessment, and conformal coating thickness mapping using multi-pass depth fusion
• Mold & Die Manufacturing: Mold cavity verification pre- and post-polishing; shrinkage analysis of prototype injection-molded parts against nominal CAD
• Medical Device Production: Validation of orthopedic implant geometries per ISO 14242-2; dimensional stability testing of polymer-based surgical guides

FAQ

What certification standards does the ActiveScan meet for metrological traceability?

The system is supplied with factory calibration certificates traceable to NIST and PTB standards; periodic verification follows ISO 10360-8 procedures and can be performed under ISO/IEC 17025 accreditation.
Can the ActiveScan be used in temperature-controlled cleanrooms?

Yes—operational range extends from 10 °C to 35 °C with humidity tolerance up to 80% RH non-condensing; optional ESD-safe variants are available upon request.
Is photogrammetry integration mandatory for large-part measurement?

No—it is optional but recommended for volumes exceeding 2 m³; standalone operation remains valid for parts within the calibrated volume of the selected lens configuration.
How is software licensing managed for multi-user enterprise deployments?

Floating license servers support concurrent user pools with centralized administration, SSO integration (SAML 2.0), and usage analytics exportable for internal compliance review.