ZEISS Car Body Solutions

Challenges

• Despite advanced digital tools, clay modeling remains central to the development process.
• The combination of CAD data, simulations, and results from clay models and wind tunnel tests is crucial for precisely coordinating construction, aerodynamics, and design.

Your benefits with ZEISS

• Optical 3D scanning captures the entire surface as a high-resolution 3D point cloud.
• ZEISS REVERSE ENGINEERING facilitates new developments and the iterative optimization of CAD data and tool geometries.

Challenges

• Design and manufacturing tools must precisely reflect the specifications of vehicle components to ensure stable and reproducible part quality.
• During the first article inspection, the team tests the first part of a new tool to verify its dimensional and shape accuracy.

Your benefits with ZEISS

• Multisensor measurements of multiple features enable fast, reliable, and precise inspection cycles.
• Tactile measurement systems reliably capture even complex geometries — even on shiny or hard-to-reach surfaces.
  

Challenges

• After stamping, forming, or casting, inspectors must check the parts for correct dimensions and ensure they meet defined tolerances.
• Dimensional measurements and surface inspections ensure that shapes and dimensions are correct and detect surface defects such as dents at an early stage.

Your benefits with ZEISS

• ZEISS ScanBox enables automated full-field 3D measurement of parts and generates a geometrical digital twin within minutes.
• Automated surface inspection with ZEISS ABIS III works reproducibly and objectively, enabling rapid quality control and targeted root-cause analysis.

Challenges

• Throughout the entire joining process, the dimensions and tolerances of all parts must be monitored to ensure a precise fit and proper functioning.
• Flush and gap inspections during car body construction are crucial for the visual quality, aerodynamics, and subsequent vehicle performance.
• Surface defects, such as scratches or dents, are detected early to ensure optimal painting preparation.

Your benefits with ZEISS

• ZEISS ScanBox enables the automated full-field measurement of parts and quickly creates a geometrical digital twin.
• Virtual Clamping replaces complex and expensive physical fixtures.
• ZEISS INSPECT allows the functional dimensions of all parts to be analyzed precisely in virtual assembly.
• ZEISS ABIS III detects even the smallest surface defects in real time during ongoing production.
  

Challenges

• After painting, car bodies and parts must be inspected for shape, fit accuracy, and surface quality.
• Factors such as temperature changes, vibrations, or part replacement can alter paintwork and car body tolerances.

Your benefits with ZEISS

• ZEISS multisensory CMMs inspect parts after painting to ensure their shape and fit remain accurate.
• Automated measurements deliver reproducible, objective results, support rapid quality control, and facilitate root cause analysis in the event of deviations.
  

Challenges

• All components must fit together precisely to meet with functionality, safety, and design standards.
• The dimensions, fit accuracy, and function are inspected on the finished vehicle.
• Flush and gap inspections ensure visual quality impression, aerodynamics, and vehicle function.

Your benefits with ZEISS

• Tactile and optical measurement systems precisely measure the entire vehicle or individual subassemblies.
• The system automatically merges all measurement data from individual parts and the vehicle for digital assembly.
• ZEISS INSPECT enables precise analysis of functional dimensions and simplifies final inspection at the part and vehicle level.