As a manufacturing operation, you want to keep costs to a minimum and product quality at its highest. Wall thickness is one of many parameters that must be accurate to produce viable components, so MicronPA offers CT scanning wall thickness analysis and wall thickness inspection services to identify optimal thickness and maintain part quality.
What Is a Wall Thickness Analysis?
Wall thickness analysis is a measurement technique that visualizes material distributions and thickness across a part. It determines if the wall thickness is within a design’s tolerances and if it will perform correctly. Our material distribution analysis via CT scanning provides a complete 3D view of wall thickness measurement across the entire part, not just at sampled cross-sections. Thickness measurements are taken from one surface on a model or part to the opposite surface.
Often, wall thickness analysis is an essential part of component manufacturing.
Where Is Wall Thickness Analysis Useful?
Wall thickness measurement is common practice when material distribution can be inconsistent. It’s also valuable in high-precision industries. Examples of uses for wall thickness analysis include:
- Automotive and aerospace: In these industries, parts must be produced in adherence to tight tolerances. Nondestructive wall thickness testing ensures these components meet safety standards and performance specifications without damaging the part, particularly for small engine components such as fuel injectors, valves, brackets, injection-molded housings, and electrical connectors.
- Plastics and cast parts: Casting wall thickness inspection and thin wall inspection via CT are particularly valuable for plastic and cast parts, where inconsistent material distribution is a common risk. This analysis helps identify defects like voids or weak points that could affect the part’s performance or durability.
- Oil and gas: Companies in this sector may use wall thickness measurements for compact components such as pipe fittings, valves, connectors and couplings used in instrumentation or control systems. Regular monitoring helps prevent leaks and environmental hazards, ensuring the safe transport of hydrocarbons.
- Medical device manufacturing: Businesses producing small implants or other medical devices require precise wall thickness measurements for the safety and performance of products like stents, catheters and prosthetics. In this highly regulated industry, ensuring the right thickness is vital for biocompatibility and functionality.
- Electronics and consumer products: Components such as electronic housings, battery casings, heat sinks and circuit board enclosures often require precise wall thickness analysis for optimal thermal management, structural integrity and regulatory compliance.
- Tooling and precision machining: Inserts, bushings and custom tooling parts with hollow features may require wall thickness analysis to verify uniformity and consistent product quality before mass production.
Professionals in many roles may request wall thickness measurements as part of supplier quality assessments or incoming inspection processes to ensure product quality and reliability, including:
- Procurement managers
- Quality control managers
- Engineering managers
- Operation managers
- Compliance managers
- Manufacturing engineers
Safety officers may request wall thickness measurements to assess the structural integrity of equipment or infrastructure to prevent accidents.
What Are the Benefits of Checking Wall Thickness?
Measuring the wall thickness of parts can be beneficial to manufacturing operations in a few ways:
- Cost savings: A primary benefit of wall thickness analysis is reduced production costs. Identifying the optimal wall thickness tolerance analysis early helps reduce material use and avoid costly scraps.
- Increased efficiency: If you don’t know the ideal thickness, you may make parts that weigh too much or use excess material, which can lead to delays or excess waste. Inaccurate weights or measurements can create problems during the casting process.
- Better designs: Using computer-aided design (CAD) to measure nominal wall thickness allows us to compare the thickness to scanned data. The comparison improves your designs and ensures your product meets design requirements.
- Happier customers: The more your product meets design requirements and the better they stay within tolerances, the more satisfied your clients are likely to be.
How We Measure Wall Thickness
MicronPA uses nondestructive computed tomography (CT) scanning to measure wall thickness. CT scanning employs X-rays to capture multiple cross-sectional images of the object from different angles. Specialized software then combines the images to form an accurate three-dimensional model. CT scanning allows us to get an inside view of the part without having to break it apart to examine it. The method preserves your sample’s integrity.
Using a CT scanner also allows us to get a more accurate and complete measurement of a wall’s thickness compared to manual methods, which provides a more comprehensive view of a design’s accuracy. CT scanning is also ideal when you need to measure the wall thickness of very small parts. Our process for measuring wall thickness includes:
- Scanning: The scanner creates an internal and external boundary around the evaluated part during the analysis. It measures the distance between each surface to find the wall thickness.
- 3D modeling: A CT scan wall thickness color map uses color coding to show thickness variations and highlight deviations from nominal. Color-coding highlights weak areas in the part or areas where the thickness is an unwanted value. Detecting weaknesses or other problems minimizes potentially expensive production errors.
- Comparison: After scanning a part, we can compare the scan results to a CAD model, using color coding to highlight any differences between the actual part and the model. When manufacturers better understand a component’s material distribution, they can make accurate adjustments to their production processes.
The size of objects suitable for CT scanning is dictated by the scanning envelope of a particular CT system. The CT scanning envelope is the maximum size the system can accommodate in one pass. For instance, MicronPA’s CT system has an envelope of 9 inches.
Objects with larger dimensions and more complex geometries call for alternative inspection methods or a system with a larger scanning envelope. Knowing these limitations will help you select the most appropriate solution for measuring the wall thickness of your products.
MicronPA Is Your Single Source for Inspection Services
MicronPA uses a personalized approach to inspection services by taking the time to understand your unique manufacturing and business requirements. While we can offer wall thickness analysis as a stand-alone service, we also provide a range of other inspection types to validate component accuracy.
We value your time, so we efficiently handle your wall thickness analysis to keep you on schedule. Our responsive client service and fast turnaround times ensure you get the inspection services you need when you need them.
Our Dimensional Inspection Services
MicronPA offers a wide range of dimensional inspection services to meet the rigorous demands of your industry. Our state-of-the-art 3D metrology services include:
- Industrial CT scanning for detailed dimensional analysis.
- First article inspection (FAI) to ensure your initial products meet all specifications before mass production.
- Last article inspection (LAI), which serves to validate that the final products continue to meet required standards.
- Production part approval process (PPAP) that’s specifically tailored for the automotive industry to ensure compliance.
- Gage repeatability and reproducibility (GR&R) studies that assess the accuracy and reliability of measurement systems.
- Geometric dimensioning and tolerancing (GD&T) analysis to maintain precision in complex geometries.
- Process capability studies that allow for the evaluation of your processes’ ability to produce products within specified tolerances.
Why Choose Our Dimensional Inspection Services?
Our dimensional inspection services are designed to provide you with confidence in the accuracy of your instruments and measurements. We understand that the quest for quality and accuracy drives many companies to seek reliable metrology solutions. By choosing MicronPA, you benefit from:
- Fast turnaround: We deliver results within five business days, minimizing downtime while maintaining the highest quality of service.
- Local expertise: As a family-owned company in Pennsylvania, we prioritize building long-term relationships with our clients based on trust and transparency.
- Customized solutions: We understand that every operation is unique, which is why we offer personalized service and free estimates with no hidden fees.
- Commitment to quality: Our rigorous adherence to industry standards ensures you can rely on our certifications and services to withstand scrutiny.
Contact Us for Nondestructive Wall Thickness Measurement
MicronPA operates out of a certified and accredited lab in York, PA, and we serve companies in Pennsylvania and beyond. Request a free quote today to get started, or get in touch with us to learn more about our capabilities. Our team is ready to assist you with your wall thickness measurement needs and ensure your manufacturing processes are as efficient and effective as possible.
