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Product optimization for casting and post-casting manufacturing processes is becoming compulsory to compete in the current global manufacturing scenario. Casting design, simulation and verification tools are becoming crucial for eliminating oversized dimensions without affecting the casting component functionality. Thus, material and production costs decrease to maintain the foundry process profitable on the large-scale component supplier market. New measurement methods, such as dense matching techniques, rely on surface texture of casting parts to enable the 3D dense reconstruction of surface points without the need of an active light source as usually applied with 3D scanning optical sensors. This paper presents the accuracy evaluation of dense matching based approaches for casting part verification. It compares the accuracy obtained by dense matching technique with already certified and validated optical measuring methods. This uncertainty evaluation exercise considers both artificial targets and key natural points to quantify the possibilities and scope of each approximation. Obtained results, for both lab and workshop conditions, show that this image data processing procedure is fit for purpose to fulfill the required measurement tolerances for casting part manufacturing processes.

An engineering validation of a large optical telescope consists of executing major performing tests at the subsystem level to verify the overall engineering performance of the observatory. Thus, the relative pointing error verification of the telescope mount assembly subsystem is of special interest to guarantee the absolute pointing performance of the large synoptic survey telescope. This paper presents a new verification method for the relative pointing error assessment of the telescope mount assembly, based on laser tracker technology and several fiducial points fixed to the floor. Monte-Carlo-based simulation results show that the presented methodology is fit for purpose, even if floor movement occurs due to temperature variation during the measurement acquisition process. A further research about laser tracker technology integration into the telescope structure may suggest that such laser tracker technology could be permanently installed in the telescope in order to provide an active alignment system that aims to detect and correct possible misalignment between mirrors or to provide the required mirror positioning verification accuracy after maintenance activities. The obtained results show that two on-board laser tracker systems combined with eight measurement targets could result in measurement uncertainties that are better than 1 arcsec, which would provide a reliable built-in metrology tool for large telescopes.

Nowadays, errors during the manufacturing process of high value components are not acceptable in driving industries such as energy and transportation. Sectors such as aerospace, automotive, shipbuilding, nuclear power, large science facilities or wind power need complex and accurate components that demand close measurements and fast feedback into their manufacturing processes. New measuring technologies are already available in machine tools, including integrated touch probes and fast interface capabilities. They provide the possibility to measure the workpiece in-machine during or after its manufacture, maintaining the original setup of the workpiece and avoiding the manufacturing process from being interrupted to transport the workpiece to a measuring position. However, the traceability of the measurement process on a machine tool is not ensured yet and measurement data is still not fully reliable enough for process control or product validation. The scientific objective is to determine the uncertainty on a machine tool measurement and, therefore, convert it into a machine integrated traceable measuring process. For that purpose, an error budget should consider error sources such as the machine tools, components under measurement and the interactions between both of them. This paper reviews all those uncertainty sources, being mainly focused on those related to the machine tool, either on the process of geometric error assessment of the machine or on the technology employed to probe the measurand.