Metrology, the science of measurement, supports excellence for every manufacturer in every sector of industry. That’s no empty boast. Big or small, new or old, any professional organization that wants to make stuff in a safe, reliable, efficient, and profitable manner must employ the tools of metrology. Otherwise, they won’t be making their stuff for long.

Those in emerging industries, with complex and unique inspection challenges, are especially well-suited to maximize the advantages of metrology hardware, software, and peripherals. To see how and why, look no further than the manufacturing processes that have developed around electric vehicles. This sector is revolutionizing the way cars are assembled and inspected, and advanced metrology solutions will help lead the way to ever-higher levels of quality and safety in the years to come.

Internal combustion engines literally drove progress throughout the 20^th century, but a combination of forces have led automotive manufacturers across the world to rapidly build new EV facilities, as well as converting existing combustion-engine factories to EV ones. Although there are certainly many similarities in how electric and internal combustion vehicles are assembled and inspected, there are enough significant differences to demand new and flexible approaches to metrology.

To take an obvious example, consider the importance of advanced metrology tools for the inspection of lithium-ion batteries. Electric vehicles contain thousands of these battery cells, which store energy to power the motor. Inspecting the functioning of these cells, and the various geometries into which they are assembled, is of critical importance. This not only allows for the proper mechanical operation of the vehicle, but also ensures that it operates safely, too.

The inspection of EV battery cells must account for tiny interior features, such as positive and negative electrodes and the separator that keeps them apart. Cracks, structural flaws, short circuits, contamination, and other defects need to be identified quickly and reliably. Advanced metrology equipment such as X-ray CT scanners, laser radar, or other vision and optical equipment offer nondestructive and automated options for inspection. The data captured by the hardware is then analyzed by powerful software to spot trends and help technicians identify ways to improve throughput and manufacturing quality.

Other applications within the EV industry are also well-served by metrology solutions. Examples include research and development of motors and drivetrains, internal inspection of sensors, and traditional automotive applications such as gap-and-flush analysis and surface analysis. All of this comes together to help those who are manufacturing within the ultra-competitive electric vehicle space create high-quality and safe cars that will provide value for their owners for many miles down the road.

These issues are important to all of us at the Coordinate Metrology Society, and not only for those within the EV automotive industry. Internal-combustion automotive manufacturers, aerospace manufacturers, semiconductor fabs, medical device manufacturers, and many more all embrace metrology as one of their key “languages” of quality.

If you are part of a community of manufacturing excellence, we invite you to visit us online, explore membership, and consider joining us at CMSC 2024. Our annual conference is coming up in Charlotte, North Carolina, from July 22–25. You can learn more and register here.