3D scanning as part of the PPAP process in the automotive industry

The scanning of plastic parts at our customer, a subcontractor in the automotive industry, took place as part of the dimensional control of the PPAP process, which is a procedure precisely defined by the standard for the approval of new parts for mass production in the automotive industry.  

The supplier is responsible for this process, which follows the customer's requirements. 

3D scanning was done based on a specific request from the end customer. The main goal was to supplement the survey reports with a color map in the control report, which is becoming an increasingly frequent customer request.  

A color map represents the creation of an overlay of a 3D model of a scanned real piece with a CAD model that serves as a reference base. 

The need for 3D scanning arose from the complexity and difficulty of individual measurements on the work. The material flexibility of the plastic part, its complicated fixation in the measuring device and the subsequent repeatability of the measurement contributed to this complexity.  

Even though the measurement of the critical dimensions defined by the customer was in order, the part repeatedly did not fit during installation tests in the final assembly. This situation led to repeated inspections, root cause searches and difficult discussions between the two parties.  

3D scanning provided additional, complementary dimensions for review, and color map analysis confirmed the correctness of the subcontractor's elevation protocols.  

The obtained 3D data and its analysis contributed to the approval of the part and the production process by the end customer, and at the same time enabled their process team to react quickly, specifically in this case the assembly process was modified in the final stage. 

The entire process of dimensional control, subsequent analysis and the adoption of corrective measures has been significantly accelerated and simplified.  

Our customer – the subcontractor – particularly appreciated the streamlining of communication with the end customer.