Hexagon accelerates aerospace inspection with automation-ready device

As aerospace manufacturers race to ramp up production amid labour shortages and rising costs, Hexagon’s Manufacturing Intelligence division has launched the Leica Absolute Tracker ATS800 – a next-generation laser tracker for high-mix, large-structure production environments. The system represents an entirely new quality inspection solution in large-scale manufacturing areas such as aerospace and wind energy, delivering direct scanning accuracy comparable to reflector measurement systems, packaged within a highly portable lightweight design.

With seamless integration into digital and robotic automation workflows, the ATS800 dramatically reduces inspection time while enabling real-time measurement and process alignment. A key innovation is FeatureDetect, an automatic feature recognition capability that identifies key part geometries without the need for manual programming. By reducing operator workload, FeatureDetect unlocks significant productivity gains in both automated and manual inspection processes.

FeatureDetect operates from CAD data or independently, using the ATS800’s built in high-resolution panoramic camera. This wide aspect live image feed allows the system to recognise features directly from the physical part, accelerating set-up and streamlining inspection.

Engineered for safety-critical industries where manual inspection of large and complex structures often creates bottlenecks, the ATS800 combines high-accuracy direct scanning and reflector tracking in a single compact system. With setup times reduced from hours to minutes, it supports unattended or in-process inspection – from fuselage alignment to composite layups – without compromising on accuracy or traceability.

“Today’s manufacturers are under immense pressure to increase output while maintaining the highest quality standards, and traditional labour-intensive processes can’t keep pace,” said Rodrigo Alfaia, Laser Tracker Product Director at Hexagon. “The ATS800 eliminates hours of setup and ‘boots-on-the-ground’ measurement activity without sacrificing precision. We’re physically and digitally automating large-scale inspection by bringing data-driven processes to the operational level, whether scanning a full fuselage overnight or guiding critical assembly processes in real time without the need for complex operator training.”

Digitally automated high-accuracy scanning
The ATS800 merges Hexagon’s renowned laser tracker technology with high performance direct scanning, in a single compact device. Performing high-accuracy reflectorless measurements at ranges of up to 40 metres, the ATS800 captures detailed data on key features like edges, holes, slots and threads without physical contact or close-proximity scanning. For even greater flexibility, full 3D reflector tracking capability further accelerates alignment and set-up processes across large-structure inspection and assemblies.

New AI-powered FeatureDetect technology removes a significant bottleneck in large-structure metrology by identifying what to measure and how. Operating from CAD or panoramic camera view, it streamlines programming and enables more agile, autonomous workflows with less reliance on experts.

Compatible with widely used metrology software platforms such as PC-DMIS, SpatialAnalyzer and third-party alternatives, the system fits easily into existing inspection workflows. It’s automation-ready, offering customers a plug-and-play path to scalable, high-throughput inspection through using the HxGN Robotic Automation software.

Robotic and AGV/AMR automation
Despite its advanced capabilities, the ATS800 has been engineered with portability and deployment flexibility in mind. Its compact form factor allows for flexible mounting in any orientation – even upside down – and seamless deployment on AMRs, gantries, lifts, rails and robot arms, supporting safe, space-efficient operations on busy shop floors.

With a well-established and fully supported SDK, the ATS800 can be embedded into complex robotic workflows, enabling automated feature measurement, dynamic part tracking and closed-loop process control in real time. Whether integrated with a fixed station lift-and-rail combination, or patrolling large assemblies on an AMR, the ATS800 gives engineers a versatile metrology solution for lights-out inspection or continuous quality assurance.

For example, the ATS800 will be powering Hexagon’s latest PRESTO Quality Stations, where it is combined with high-speed 2 axis positioning to automate the inspection of automotive chassis features. Using long range, reflectorless scanning, multiple complex features are inspected with only single axis movement on a vertical lift or horizontal rail - drastically reducing cycle times and increasing repeatability and throughput.

Unlocking “third-shift” workflows and real-time assembly
As production scales across aerospace and other large-structure industries, the ability to perform overnight or in-process inspection is becoming essential. The ATS800 unlocks ‘third-shift’ workflows with unattended scanning, real-time tracking, and subassembly alignment – all backed by full digital traceability. Whether guiding fuselage integration or layer-by-layer composite inspection, it ensures high precision without interrupting workflows.

At the heart of the system is Hexagon’s TruePoint Interferometer, a next-generation measurement engine that minimises noise and delivers pinpoint accuracy, even on challenging surfaces or at very steep angles.

When mobility is required, Hexagon’s proprietary PowerLock reacquisition technology instantly re-locks onto reflectors in motion, ensuring continuous measurement during real-time assembly.

www.hexagon.com