„Terahertz measurement technology replaces complex manual inspection with a fully automated solution, taking quality assurance to an entirely new level,“ says Christoph Theiselmann, Head of Exterior Plastics, Production at Plant Leipzig. At the heart of the system is the terahertz measurement system Irys, developed by das-Nano specifically for industrial inline inspections. The system enables contactless, non destructive measurement of multi layer paint systems and delivers real-time data, representing a significant advance over previous inspection methods.
Inline measurement
Until now, paint layer thickness inspections on plastic exterior components at Plant Leipzig have been carried out manually during production, using scalpels and microscopy, thereby destroying parts in the process. Terahertz technology fundamentally transforms this process: sensors mounted on two robots in the existing end-of-line measurement cell are automatically and precisely positioned in relation to the component, where they measure the thickness of the individual paint layers by analysing the time-of-flight of reflected terahertz waves. Measurements take only seconds and achieve accuracy down to the micrometre level. The new technology not only delivers objective and reproducible measurement results, but also enables the early detection of process deviations. The resulting digital measurement data enhance transparency within production and provide a robust foundation for data-driven process control.
Following the introduction of automated surface inspection in 2024, terahertz measurement technology marks the next step towards a fully digital paint shop for plastic components at Leipzig. The measurement and quality data it generates are available entirely in digital form, creating the basis for advanced data-supported analysis. In the future, this data will be analysed using AI-based methods to identify deviations early, evaluate trends and continuously optimise process parameters.
Outlook
Following successful piloting and ramp-up, the new technology can now be deployed with all component carrier systems, or ’skids‘, and is currently being enabled for all colour variants as well. It also offers significant potential for rollout at other plants, particularly in painted body shops and across the supplier network.
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