Automotive Flange Case Study TFG USA 3 090120

Optical Measurement Innovation

How To Meet The Print Without Breaking The Bank. A case study in optical measurement innovation using automotive flanges manufactured by TFG USA.

Automotive Flange Case Study TFG USA 090120

Introduction – small businesses need accurate measurements too

You have a small manufacturing business. But, you still need accurate dimensions for your production part qualification process. You can’t afford a full-blown metrology department with a giant CMM (coordinate measuring machine).

There is an innovative solution using machine vision to measure your parts. A high-resolution off-the-shelf scanner can be combined with a free optical measurement analysis program to get you the accuracy you need. You can now enjoy this new part measurement capability.

It’s a new complement to our suite of measurement devices now available for you.

Pictured Right / Above: The high-resolution scanner we used for this case study.

Advantages of optical measurement software

Optical measurement is a fast, economical way to measure features on planar surfaces.

Here are some ways that you can benefit from optical measurement software:

Measurement values can be displayed using custom number formats—as required by you or your customer.
Theoretical features can easily be calculated and displayed (e.g., locations of theoretical sharp corners formed by two edges or the center of a hole.
Critical fitment data can be easily calculated and displayed (e.g., the distance between centers of two holes—to fit over two studs on the mating part).
Custom variables can be defined for plotting and analysis.
Editable text columns for comments or manual data entry can be easily added.
Data (raw or formatted) can be easily exported to a spreadsheet or other analytical software for additional analysis.

Automotive Flange Case Study TFG USA rendering

Pictured Left / Above: Illustration depicting critical fitment between threaded studs and the hole centers of the CNC-Machined Automotive Flanges (described in this case study)

Applications – accuracy without the complex setup

The inspection process demands accurate measurements. Every measurement system has its strengths and weaknesses.

The strength of this measurement methodology is that it provides capabilities that aren’t easily achievable with other available tools. The distance between hole centers is often a critical fitment criteria. Getting accurate manual measurements is tedious.

By establishing points on the arc of the circle, you can calculate the center point. The benefit of this methodology is that you can easily determine center-to-center distance conformance to the fitment criteria after you calculate the center points of two or more holes.

Pictured Right / Above: Calibration stick in blue. This is a measurement of a product. In red is the calculated distance between the center points of two holes—a tough measurement to get manually.

Observations – methodology leads to repeatability

This measurement methodology gives you high resolution — less than +/- 0.001” linear and less than 0.5° angular. The scanner resolution is critical for measurement accuracy.

The system is limited to the evaluation of planar / flat surfaces that will fit on the scanner bed (roughly 8.5″ x 11″ for our current setup). When used skillfully, it can give you an accurate visual record of the part analysis (see below).

Measurement systems that are not fully autonomous are susceptible to user variation (i.e., the user must accurately place the software’s visual markers on part characteristics).

Our operators are trained to produce accurate and repeatable measurement results for you.

Conclusions – accuracy with economy

It was possible to build a cost-effective optical measurement system with off-the-shelf parts and readily-available software.

This system fills the need for many clients who need accuracy with economy.

We were able to understand the strengths and weaknesses of this measurement methodology to use them to our customer’s optimal advantage.

Now it’s your turn

If the thought of accurate, economical measurements appeals to you, then contact us to learn how we deliver precision quality parts to customers just like you.

     Excellent  
     Based on 12 reviews 
    
 
 
   
 
 
        
   Jonathon Lanham 
 2025-09-26
 
 
 Trustindex verifies that the original source of the review is Google. Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!
  
 
       
   Sean Brockhouse 
 2025-04-20
 
 
 Trustindex verifies that the original source of the review is Google. Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines.  Outstanding customer service!!
  
 
       
   Melissa Quiroz 
 2024-08-09
 
 
 Trustindex verifies that the original source of the review is Google. Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!
  
 
       
   Alex Armstrong 
 2023-12-15
 
 
 Trustindex verifies that the original source of the review is Google. Steve was great to work with and was always available when needed.
  
 
       
   Jon Ramsey 
 2023-10-07
 
 
 Trustindex verifies that the original source of the review is Google. Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success.

Would recommend and I plan to use them for future projects.

Thanks again Mike and TFG team.
  
 
       
   Nic Robinson 
 2023-10-05
 
 
 Trustindex verifies that the original source of the review is Google. Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.
  
 
       
   Sean Connelly 
 2023-06-21
 
 
 Trustindex verifies that the original source of the review is Google. The Federal Group was great to work with. Steve was very professional and diligent in providing good advice/feedback as well as following up with me. Look forward to working with them in the future as well!
  
 
       
   Sher Stahl 
 2020-07-10
 
 
 Trustindex verifies that the original source of the review is Google. The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.
  
 
       
   Marshall 
 2020-06-30
 
 
 Trustindex verifies that the original source of the review is Google. Excellent customer service and products!