Trade fair highlight 04. September 2025

A real-time monitoring system for stamped components and tooling in high-speed multi-stage forming processes has been developed using photometric stereo. The scanner is integrated into an idle station. During production, the ram clamps the component while the scanner captures a sequence of images under varied illumination to compute a surface normal map. This 2.5D data is compared in real-time with a reference model trained on approximately 100 cycles of defect free parts to quantify deviations from target. The system detects deviations at up to 400 strokes per minute with 10 µm accuracy and supports correlation of detected deviations with wear across the forming stages. The project received the EFB Excellence Award in 2025.