Small Parts, Big Challenges: How High-Precision 3D Scanning Makes Full-Field Inspection Simple

Small parts, big challenges. Discover how SHINING 3D Metrology's OptimScan Series makes full-field inspection of injection molded components fast, accurate, and hassle-free—backed by a real-world success story.

If you've ever looked inside a car's electronic system or opened up a household appliance, you've seen them—small plastic parts like connectors, relay housings, sensor casings, and switch components. These little pieces may not look like much, but they play a big role. They hold things together, protect sensitive electronics, and need to fit perfectly with other parts. A tiny deviation—barely noticeable to the eye—can cause assembly problems or affect how the whole product performs.

That's why getting dimensions right matters so much. But for manufacturers who deal with these small parts every day, measuring them accurately is easier said than done.

A Real-World Challenge: Zhenying Electromechanical

Zhuhai Zhenying Electromechanical Co., Ltd., founded in 2005, makes automotive electronic devices and body electronic control systems. Many of the parts they produce are small—some just 10 mm, others up to 100 mm. And they need to meet tight quality standards.

When developing a new product, Zhenying often has to measure 100 to 200 dimensions on a single part. In the past, that meant using 2D image measuring instruments and CMMs, with operators measuring one dimension at a time. Each measurement required a new setup, and the part had to be refixtured over and over. It was slow, exhausting, and made full-field inspection nearly impossible. When a customer asked for a full inspection report, the team often had to outsource the work.

Small parts come with their own set of challenges. They're tiny, so you need equipment that can capture fine details without missing anything. Their shapes are often complex—think thin walls, tiny ribs, and small bosses. And because they're injection molded, they can have subtle warping or shrink marks that are hard to spot with traditional tools. On top of that, measuring dozens or even hundreds of dimensions on each part takes a huge amount of time and labor.

For Zhenying, it was clear they needed a better way.

High-Precision 3D Inspection System Becomes the Key Soluton

When Zhenying Electromechanical learned about high-precision 3D scanning technology, they approached SHINING 3D and selected OptimScan Series, easily enabling full-field inspection of their small injection molded parts.

A New Approach to Full-Field Inspection

Using OptimScan Series, accurate and complete 3D data of the small injection molded parts is acquired. This 3D data is then imported into professional inspection software and compared with the design data. A color map intuitively displays the form and position deviations.

Simultaneously, individual dimensions can be measured within the software. Regardless of how many dimensions need to be measured, they can be inspected rapidly, with no upper limit on the number of dimensions.

Through this high-precision 3D inspection method, a single scan, with a single setup, completes the full-field inspection, completely transforming the previous model of measuring dimensions one by one. Efficiency has increased exponentially, making full-size inspection of small injection molded parts a practical reality.

Features of OptimScan Series

As an emerging measurement method, its ability to successfully perform full-field inspection of small injection molded parts relies heavily on the device's application characteristics.

Measurement Accuracy: As a measurement tool, accuracy is a fundamental requirement. OptimScan series offer metrology-grade precision, with accuracy up to 0.005 mm and stable repeatability, accurately capturing the dimensional information of the workpiece.

Certification: Based on VDI/VDE 2634 Part 2 standards. Evaluation of probing error performance based on traceable sphere diameter measurement data. Evaluation of sphere spacing error based on measurements from a fixed position perspective within the working volume using a traceable length standard.

"Our measurement accuracy requirements are quite high, often at the micron level. The accuracy of this 3D scanner meets our needs, and its repeatability is very stable, with results closely matching our measurements from the 2D image measuring instrument. Moreover, the device's detail reproduction is excellent. We have conducted repeated verifications, and the equipment performs well in all aspects."

— Ms. Luo, IQC Section Chief, Zhuhai Zhenying Electromechanical Co., Ltd.

Measurement Efficiency: When paired with a 2-axis rotary table, the OptimScan Series enables automated scanning, completing the scan in just 1-2 minutes. The entire measurement process, from scan to report, can be completed within half an hour. This high efficiency is precisely what makes implementing full-field inspection feasible.

Leveraging advantages such as metrology-grade accuracy, powerful detail reproduction capabilities, and high measurement efficiency, the OptimScan Series equipment holds a strong position in the full-field inspection of small injection molded parts.

With this new approach, Zhenying went from measuring one dimension at a time to capturing everything in a single scan. Full-field inspection is no longer a bottleneck. They can now provide full inspection reports whenever customers ask for them, and the whole process takes much less manual work. It's a clear win for both quality and efficiency—and a great example of how the right technology can turn a frustrating challenge into a straightforward solution.

Small Parts, Big Challenges: How High-Precision 3D Scanning Makes Full-Field Inspection Simple

A Real-World Challenge: Zhenying Electromechanical

High-Precision 3D Inspection System Becomes the Key Soluton

A New Approach to Full-Field Inspection

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Features of OptimScan Series

OptimScan Series