Advanced manufacturing enables novel design and production techniques for industrial products with complex freeform geometries. It also meets the increasing demand for fast and contactless measurements in industrial quality control using optical sensors. However, current simulation-based methods using Digital-Metrological Twins (D-MTs) to determine measurement uncertainty do not cover such developments in advanced manufacturing. To address this issue, this project will develop reliable model descriptions, accurate mathematical models for use in D-MTs, traceable parametrisation methods for measurement uncertainty evaluation in D-MTs. The project will also optimise the performance of the developed D-MTs for advanced manufacturing applications, as well as producing case studies comparing optical and tactile measurements using complex freeform geometries and guidance for D-MT use in advanced industrial applications.

The overall goal of the project is to provide methods and tools in metrology for advanced manufacturing processes to suit the needs arising from a paradigm shift in part properties and measurement techniques. In particular, mathematical descriptions will be developed for optical sensor technologies and freeform-shaped workpieces that take into account the relevant uncertainty contributions. The mathematical models will be usable for D-MTs and represent measurement processes, CMMs, MTs, and workpieces in industrial applications.

The specific objectives are:

1. To determine the measurement uncertainty sources attributed to freeform geometries, and to develop accurate mathematical models for use in D-MTs. This includes the (i) evaluation of the D-MTs, (ii) the experimental comparison of the deviations of freeform geometries to prismatic standards, and (iii) the creation of virtual reference artefacts for representative freeform standards.
2. To evaluate the behaviour and inherent properties of at least 3 different types of optical sensors integrated in CMMs and/or MTs. This includes the determination of the influence of (i) surface characteristics, (ii) surface tilt and (iii) curvature on the interaction between the optical sensors for freeform and prismatic geometries, as well as the development of reliable mathematical models for D-MTs.
3. To develop methods for the traceable parameterisation of models used for measurement uncertainty evaluation in D-MTs. This includes the identification of suitable measurement standards and procedures for the parameterisation of D-MTs and the development of parameterisation strategies for (i) freeform geometry measurements and (ii) for optical sensor measurements.
4. Using the D-MTs developed in Objectives 1-3, to optimise their performance for economically efficient application in advanced manufacturing. This will include case studies comparing optical and tactile measurements using freeform geometries and prismatic parts in order to (i) verify D-MT application and (ii) to produce good practice guidelines for D-MT use.
5. To facilitate the take up of the technology and measurement infrastructure developed in the project by the EMN Advanced Manufacturing, the measurement supply chain, standards developing organisations (e.g. ISO, VDI/VDE-GMA), and end users (e.g. automotive, machine industry, micromanufacturing, renewable energy and medical sectors).

The publishable summary describes the need, progress beyond the state of the art and potential outcomes and impact of the project.

The data management plan describes how research data generated in the project will be managed to ensure that these are Findable, Accessible, Interoperable and Re-Usuable (FAIR). This plan will be updated throughout the life of the project.

The poster presenting the project to the review conference can be seen here.