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Visual Quality Inspection for Automotive – With Augmented Reality, CAD & Twyn

Why Augmented Reality for Quality Inspections?

It's mobile, fast and intuitive – for reliable & convenient inspections

Visual Quality Inspection with AR and Twyn has found its way into the automotive industry for good reasons: it enables mobile, fast & intuitive, yet reliable & convenient inspections.

Interactive Target/Actual Comparison: Through AR overlays on a tablet, operators can easily match manufactured items against their digital twins.

AR superimposes CAD specs directly on manufactured items and inspectors can visually verify if parts differ from CAD, or if they are properly produced.

Easily create inspection plans and perform inspections in real time – regardless of where parts are produced or stored.

This makes it fast, intuitive and convenient to check if:

  • parts have their geometric features exactly where they are supposed to be
  • assemblies have missing parts
  • components are properly assembled
Reporting Twyn Optical Quality Inspection

Improved and Simplified Processes: from Inspection Preparation to Enhanced Collaboration

Fast & flexible mobile inspection and real-time documentation to always ensure quality

Simply import your CAD data and the solution is ready for inspection:

  • no 2D drawings or programming required
  • no hardware setup and markers are needed
  • location independent – start inspection wherever your parts are located

Neither metrology expertise nor AR knowledge are required:

  • inspection steps & viewpoints guide users and speed up inspection routines
  • operators can follow predefined inspection plans, checking predefined areas 
  • definition of inspection areas for streamlining repetitive inspection routines
  • CAD models are optimized for onsite inspection, ensuring speed and optimal user experience

Inspecting and document results at the same time:

  • direct inspection results’ visualization
  • real-time on-site textual and visual annotations

Comprehensive reporting & result recirculation:

  • customizable, digital reports to be shared in multiple formats with internal departments and suppliers
  • projects and reports can be shared across different IT platforms

Inspections Based On CAD-Model

Minimum setup, focus on inspections

Without the need of any additional software, Twyn allows to prepare, simplify and optimize CAD structures, eliminating all those details which are not relevant for the inspection routines.

This streamlines and speeds up quality checks – especially of very complex parts.

CAD data delivered by Twyn is optimized for mobile devices: minimum setup time is required, and quality inspectors can immediately focus on their inspection tasks.

Inspection Points Realigned with Twyn Augmented Reality Software

Inspection Plans – Guided Inspection with Inspection Viewpoints

Consistent procedures, results and documentation

Twyn operators can follow predefined and detailed inspection plans, checking predefined areas with multiple features.

The solution leads users with step-by-step instructions in form of comprehensive checklists. Visual indicators mark and highlight points of interest with 3D pointers, facilitating the inspections of complex assemblies.

This ensures consistent procedures, results and uniform inspection documentation – regardless of users and their experience.

Automatic, Real-Time Tracking and Registration

Fast yet accurate visual comparison

Localized through the tablet’s camera, Twyn automatically registers and tracks manufactured items. 

Enabling a fast yet accurate visual comparison, Twyn’s precise real-time object tracking works marker-les, without the need of any additional set-up or pre-preparation to analyze parts.

Real-Time Documentation & Reporting

Comprehensive documentation of inspection data & customizable, digital reports

Markups and annotations increase traceability and streamline the communication between quality, production, and construction teams.

Branded and customizable reports (with dedicated pictures) can be exported in multiple formats (such as XLS, CVS or PDF), and easily shared with suppliers as well.

Save time in the process and document results already while performing inspections and benefit form comprehensive functionality:

  • Photo evidence, marks & notes
  • Spatial documentation of findings
  • Classification & deviation characteristics


Application Examples

Body in White Inspection Points in Twyn AR Solution

Body-in-White Inspection in AR

Proper integration of trims and other components

Check that all geometric features of the body frame are in the right place.

That‘s a critical prerequisite for proper integration of trims and other components (e.g. door locks and handles, electronic components, seats, …), chassis, subassemblies and the engine.

What’s more, with AR you can benefit from additional workflows not possible before. For example, you can virtually check assembly steps with ›Virtual Fitting‹ by simulating the assembly in AR.

Furthermore, you can verify features for:

  • Location
  • Orientation
  • Existence
  • Amount
Verify Bolts, Studs & Welding Spots via AR Image Processing

Verify Bolts, Studs & Welding Spots

Get support through automated verification via image processing

With Twyn, it is easier and faster to perform both complex and recurring checks to ensure that all geometric features of assemblies such as a body frame are in the right place – including welding points, bolts and studs. 

Furthermore, with AR you benefit from an automated import & creation of inspection points.

The assisted import of inspection data enables you to automatically transfer them into 3D, visualize them and export the results.

All the details needed to perform inspections are generated automatically. This helps to save time not only while setting up the inspections, but also during the inspection sessions.

AR increases sampling & inspection rates, and allows to speed up recurring inspections. 


Check automotive production equipment with AR

Tools for efficient machining and assembly of parts are essential for industrial manufacturing, ensuring that components are manufactured according to specified requirements.

  • Twyn and AR are ideal for testing custom designs & solutions
  • 3D-to-3D comparison facilitates verification of those many, often complex details
  • AR digitally supports the entire realization process, while performing several runs until the final tool is built
  • Digital process, location-independent, ideal also for large components and assemblies

Jig & Fixture Construction

Check position, orientation and alignment of many moving parts

Jigs and Fixtures are important tools in manufacturing. They need proper positioning and alignment to ensure reliable machining operations. Twyn enables to check and adjust alignment in real time.

  • Ar allows to prevent costly errors and rework during fixture deployment thanks to a speedy and interactive CAD-based inspection process
  • Twyn is ideal for reporting, allowing companies to spatially document changes also with photo evidence

Incoming- & Outgoing Inspections

Easy cross-company cooperation with suppliers

AR and Twyn streamline collaboration across organizations. They allow to check if both manufactured and incoming parts respond to specifications, also enabling a smooth execution of pre-defined and shared audit plans

  • Supplier companies can check if their manufactured components meet specifications before they are shipped for further production or assembly stages (outgoing inspection)
  • Supplied companies can use AR to quickly identify incoming parts that don‘t respond to specifications before next production or assembly stages begin (incoming goods inspection)
  • Risks for production errors are caught at an early stage

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