Significant acceleration of the 3D measurement process for complex plastic parts thanks to Hexagon

Denso Manufacturing Czech s.r.o. was looking for a more efficient and accurate method for inspecting air conditioning units (HVAC) and their components: heat exchangers, fans and plastic parts. The original inspection system was no longer covered by service support, and spare parts would not have been available in the event of a breakdown. The plant therefore faced a real risk of losing a key measurement solution essential for ensuring production quality.

By acquiring the SmartScan VR800 structured-light 3D scanner, Denso Manufacturing Czech s.r.o. can now perform fast, non-contact and highly accurate inspections, even of several parts at once. This technological innovation has made it possible to reduce inspection time, improve defect detection capabilities and increase the flexibility of the entire process. The result is higher product quality and the ability to meet the demanding standards of global automotive customers.

Fast scanning of parts enables Denso to detect deviations early and thus reduce rework costs.

Denso Manufacturing Czech s.r.o., a subsidiary of the Japanese DENSO group, was established in the Czech Republic in 2001 and has been a mainstay of the automotive industry ever since. Located in the industrial zone in Liberec, it employs 2,000 skilled specialists who produce high-quality components for automotive thermal systems. As one of two key manufacturing bases in the Czech Republic, alongside Denso Czech s.r.o. in Zruč nad Sázavou, the Liberec plant specialises in thermal management systems that ensure optimal temperature conditions for both passengers and the vehicle itself.

Each year, the plant supplies approximately 2.5 million air conditioning units to leading European and Japanese car manufacturers, including Volkswagen Group, including Škoda Auto, BMW, Toyota, Suzuki, Ford and Volvo. The company's emphasis on quality is reflected in its rigorous inspection processes and use of state-of-the-art manufacturing technologies, which enable it to consistently meet the high standards of the global automotive industry.

SmartScan VR800 Scanner

Innovation Backed by a Reliable Partner

Denso Manufacturing Czech s.r.o. has maintained a close partnership with Hexagon for almost two decades, during which time it has incorporated several Hexagon solutions into its quality control processes, including GLOBAL series coordinate measuring machines, PC-DMIS metrology software and a 7-axis Absolute Arm portable measuring arm.

In 2024, the company upgraded its inspection capabilities to overcome the limitations of its previous measuring system. This system was slow at scanning and processing data, particularly with larger volumes of parts. As a result, it could not keep pace with rapid product development and production. The company therefore sought a more advanced solution and ultimately opted for the latest generation of optical scanning technology. The newly launched SmartScan VR800 scanner stood out for its high accuracy, speed and efficiency – qualities that meet the constantly growing demands of modern manufacturing.

Hexagon supported the transition to the new system with hands-on training using actual parts, enabling the Denso Manufacturing Czech s.r.o. team to start using the system in routine operations almost immediately. With four trained operators, the plant now benefits from greater flexibility and in-house expertise. Pavel Knirsch, Quality Manager at Denso Manufacturing Czech s.r.o, says: “It was important to ensure that we could adapt to the new system as quickly as possible and start using it effectively in our day-to-day work.”

Improving Quality Control of Plastic Parts Through Optical Scanning

The acquisition of the SmartScan VR800 scanner has significantly improved the inspection of plastic parts used in air-conditioning systems. These parts, often highly complex and irregularly shaped, are ideally suited to the optical scanning capabilities of the SmartScan VR800 scanner, which enable detailed surface digitisation without the need for manual point probing as in tactile measurement on stationary coordinate measuring machines. The scanner's motorised lens zoom allows the resolution and measuring range to be adjusted entirely through software, eliminating the need to change lenses manually.

The scanner is particularly effective when measuring plastic materials that are prone to deformation. As Knirsch explains: “Plastic materials are sensitive to deformation, and this is where the scanner truly excels. Thanks to fast scanning and the ability to generate colour maps, it efficiently detects deviations and changes in shape that could affect the functionality of the part.” This capability is crucial for identifying common defects, such as sink marks caused by plastic injection moulding. It thus enables precise analysis and informed corrective action.

The scanner is typically used every other day, depending on current production needs.
The workflow is organised to maximise efficiency: one day is devoted to scanning parts, such as flap actuation components, while the following day is spent on detailed evaluation of the acquired data. Separating scanning from analysis enables the team to work efficiently and respond quickly to production requirements.

While complete HVAC units undergo checks using in-line inspection machines, the SmartScan VR800 scanner is used to inspect individual components. “An air-conditioning system consists of an enormous number of parts, each of which fulfils a specific function while also having to fit precisely into the overall design,” says Knirsch. “This is particularly critical in the early stages of new projects, when individual parts are still being fine-tuned. Many parts need to be modified to ensure seamless system integration.”

Denso uses SmartScan VR800 for fast and accurate inspection of complex parts. This ensures high manufacturing quality that meets global automotive standards.

The scanning system makes it possible to scan multiple parts simultaneously, quickly and accurately, evaluate their compatibility with one another and determine which part needs to be modified and in what way so that the final product meets the customer's requirements. The acquired data is then shared with designers and suppliers, facilitating collaboration on design modifications or tolerance optimisation.

Significant Time Savings and Increased Efficiency

Thanks to its advanced features, SmartScan VR800 has significantly improved inspection processes at Denso Manufacturing Czech s.r.o., delivering time savings and increased operational efficiency. Antonín Kvasnička, Quality Team Leader, says: “One of the first visible benefits of the new system is the significant time savings. VR800 offers faster scanning and data processing compared with the previous system, which is particularly noticeable when inspecting larger volumes of parts.” This improvement makes it possible to work with large amounts of data more quickly and respond more flexibly to development or production needs.

3D scan of a small plastic air-conditioning component.

A Partnership for Progress

Denso Manufacturing Czech s.r.o. actively shares knowledge with other sites within the group with the aim of standardising measurement methodologies. The use of 3D scanning is becoming a common approach that aligns expectations, requirements and technical capabilities.

The company is optimistic about the future. With plans to introduce new products, particularly for electric vehicles and next-generation air-conditioning systems, SmartScan VR800 will be a key tool. The company is also systematically implementing measures to achieve carbon neutrality by 2030.

By adopting innovative technologies and strengthening strategic partnerships, Denso Manufacturing Czech s.r.o. continues to set standards for quality and innovation in the automotive industry. Its collaboration with Hexagon exemplifies how mutual trust and shared goals lead to remarkable progress and ensure that Denso remains at the forefront of automotive component manufacturing.

VR800 combined with a rotary table enables high-resolution 3D digitisation of cooling system components and accurate capture of fine details and complex shapes.

SmartScan VR800 Structured-Light Scanner

The Smart Zoom and Smart Resolution features of the SmartScan VR800 scanner enable critical areas to be captured at high resolution, while the rest of the part can be scanned at standard resolution. By allowing the resolution and measuring range to be adjusted exclusively through software, it significantly simplifies the inspection process.

Another feature, Smart Snap, uses four digital cameras for simultaneous scanning and marker capture. This allows photogrammetric markers to be placed outside the 3D scanning area. As a result, fewer markers are needed and the measuring range is extended, speeding up the entire scanning process.

Software-controlled adjustments provide Denso Manufacturing Czech s.r.o. with flexibility and rapid adaptation to different inspection needs without having to change lenses. The ability to integrate data with different resolutions into a single project further increases efficiency. This enables the company to process large volumes of parts, adhere to production schedules and meet its customers' stringent quality requirements.