Non Std Gauges
Non-standard customized gauging solutions refer to precision measurement tools that are specifically designed and manufactured to meet unique, specific requirements of a particular application or workpiece that cannot be met by off-the-shelf, standard gauges. These customized gauges are often used in industries where parts have complex geometries, require high precision, or are produced in low volumes, and where conventional gauges are not suitable for measurement.
uses of non-standard customized gauging solutions:
Customized gauges can be designed to measure parts with non-standard shapes, such as irregular contours, curves, grooves, or undercuts. For example, parts used in aerospace, medical devices, or automotive components often have unique or highly complex geometries that cannot be easily measured with standard gauges.
Examples: Measuring turbine blades, engine blocks, dental implants, or highly contoured castings
In industries where components require extremely tight tolerances (for instance, in aerospace, electronics, or medical devices), non-standard gauges can be created with custom specifications to ensure parts are measured to the most exacting standards.
Examples: Measuring medical surgical instruments, high-precision aerospace components, small diameter pins, or micron-level dimensions.
Non-standard gauges are often required when parts are larger or smaller than the typical range of standard gauges. Customization allows for the creation of gauges suited to measure oversized or micro-sized parts that do not fit within the capabilities of standard equipment.
Examples: Measuring large machinery components (e.g., gears, shafts, or castings), small precision electronics, or micro-scale parts like microchips or screws.
Customized gauges are highly effective for high-volume production where parts must be inspected in large quantities with minimal variation. These gauges are designed to integrate seamlessly into automated production lines* or high-speed inspection systems.
Examples: Continuous measurement of parts in automated manufacturing environments, such as cylinder heads, brake pads, or automobile engine components.
In some cases, parts have hard-to-reach features or tight tolerances that standard gauges cannot access easily. Customized solutions can be tailored to reach difficult areas or specific part features that require specialized probing or measuring techniques.
Examples: Measuring internal threads or deep holes, bores with complex geometry, or thin-walled parts.
Non-standard customized gauging solutions can be designed for use with complex assemblies where multiple parts must be measured simultaneously or where the relationship between components (e.g., clearances, alignment, depths, or fitments) must be checked as part of the inspection process.
Examples: Measuring engine components, bearing fits, or assembly of subcomponents like gearbox parts or transmission assemblies.
Non-standard gauging solutions can be specifically designed to withstand extreme environmental conditions such as high temperatures, high pressures, or corrosive environments. These gauges are made from specialized materials to endure harsh conditions.
Examples: Gauges for automotive engine testing, oil and gas industry, or high-temperature aerospace components.
Customized probes can be designed to work with CNC machines, robotic arms, or vision systems for automated inspection. These customized systems help ensure consistent measurements of parts directly on the production line or in post-production processes.
Examples: Measurement of parts in automated production lines, robot-assisted assembly or inspection of assembly parts in electronics manufacturing.
In certain cases, non-standard gauges can be customized to measure surface properties, thickness, or material hardness that cannot be measured using traditional methods. These gauges can include sensors for material testing, such as hardness testers or thickness gauges.
Examples: Measuring coatings, surface finishes, material hardness, or wall thickness of precision parts like metal sheets or coated parts.
Customized gauges are often used in the prototyping phase of product development when parts are being designed for the first time, and standard gauges do not exist for measurement. These gauges help ensure that prototypes meet design specifications and tolerances during testing and development.
Examples: Measuring prototype aerospace components, medical device prototypes, or custom automotive parts.
Advantages of Non-Standard Customized Gauging Solutions:
The most significant advantage is that custom gauges are designed to meet the exact needs of the application. This ensures optimal accuracy and precision for unique or complex geometries, dimensions, and tolerances that off-the-shelf gauges cannot measure.
Example: Customized air gauges for measuring parts with unique internal geometries or complicated forms.
Since the gauge is designed specifically for the part or application, measurement accuracy is significantly improved. The customization ensures the gauge is calibrated for the specific part geometry, materials, and tolerances, leading to highly reliable and repeatable results.
Example: A custom air gauge designed to measure small bore dimensions with high precision.
Custom gauges often integrate into automated inspection systems, allowing for faster measurements and higher throughput in production. They can be designed to handle high-volume manufacturing environments, reducing the time required for quality control and speeding up the production process.
Example: Automated in-line measurement systems using custom gauges to inspect parts like automotive components during the assembly process.
Although the initial cost of a custom gauge can be higher, it is often more cost-effective in the long run due to the reduced need for frequent recalibration, fewer scrapped parts, and the ability to maintain consistent quality throughout production. Custom gauges help minimize downtime and avoid costly production errors.
Example: A custom gauge designed for mass-production of engine parts that helps reduce rework and ensures consistent quality.
Custom gauges can be designed to meet flexible needs for various parts, even if part designs change over time. They can be adapted to new part features, dimensions, or tolerance changes, providing ongoing support for evolving production requirements.
Example: A custom multi-functional gauge designed to measure both diameters and tolerances of different components in automotive manufacturing.
Customized gauges are extremely useful in the prototype stage of product development, allowing designers and engineers to test and measure parts as they are created. This accelerates the development process, helping to quickly identify any issues with part dimensions or designs.
Example: Custom gauges used to test the dimensions of a new aerospace prototype before moving into full-scale production.
For industries where the precision of components is critical—such as in medical devices, aerospace, and automotive racing—customized gauges can be built to ensure parts meet the required standards and tolerances with utmost accuracy. These gauges can even be designed to check dynamic characteristics like vibration, fitment, or clearances during operation.
Example: Custom gauges used to measure engine components for racing vehicles, where performance depends on extremely tight tolerances.
Custom gauges can be made from specialized materials to suit extreme environments or specialized materials. For example, gauges designed for use in high-temperature environments, corrosive conditions, or clean-room environments.
Example: High-temperature gauges for measuring parts used in gas turbines or aerospace engines.
Non-standard gauges can be automated and designed with integrated feedback systems to reduce human error during measurement. Custom systems can provide real-time feedback to operators, ensuring measurements are consistently accurate and minimizing the risk of faulty parts being sent through production.
Example: Custom automated measurement systems used to check high-volume production
Customized gauges can be integrated into existing CNC machines
