For 185 years, Bharat Forge CDP has been a hallmark of expertise and craftsmanship in metal forging and forming. The German company is known worldwide as an innovative leader and trusted supplier to a wide range of industries, including automotive, rail transportation, and mechanical engineering sectors. As a manufacturer of chassis components for passenger cars and commercial vehicles, Bharat Forge maintains the highest standards of safety, precision, and innovation.

The challenge: Outgrowing traditional 3D measurement methods

With its long-standing tradition of being ahead of the curve in metal-forming and forging technologies, the company decided it needed to invest in new solutions to proactively meet customer demands. 

“As a supplier of safety-critical components, we must measure parts multiple times throughout the production process to ensure the utmost quality and comply with project specifications,” says Florian Heimbeck, inspection planner of metrology at Bharat Forge. “We simply can’t afford inaccuracies or delays in our 3D measurement processes.”

Over the years, the company’s conventional tactile 3D measuring system became more of a problem. While reliable, it required specialized operators with years of training. Even then, each complex component took up to two hours to measure—time that wasn’t viable in a fast-paced, competitive landscape. In addition, the outdated system was limited in its ability to capture intricate part geometries, meaning certain customer specifications couldn’t be fulfilled in-house.

“We often had to rely on external measurement services, which increased costs and risked delays in our production process,” Heimbeck says. “For a company with our reputation, the fear of losing follow-up orders or failing to meet the state of the art was a constant concern.”

As customer expectations grew more stringent, Bharat Forge was at a crossroads. The company needed a solution that could measure complex, free-form surfaces with speed and the highest accuracy—all while empowering more employees to take part in the 3D measurement process and breaking the reliance on a handful of specialists.

Taking metal forming and forging innovations to new heights

Determined to remain at the fore of the market, Bharat Forge began searching for more modern 3D measurement technologies. The criteria were clear: the company needed solutions capable of both tactile and optical measurements, independent of adhesive dots or surface sprays. Portability was key; the 3D measurement solutions needed to be versatile enough to measure components of all sizes and geometries without requiring the parts to be moved to a dedicated lab environment.

After evaluating several options, Bharat Forge chose Creaform’s 3D metrology solutions:

MetraSCAN 3D: Optical and portable CMM 3D scanner

HandyPROBE: An arm-free portable probing system designed for the shop floor

VXinspect: Dimensional inspection software module

Transitioning to new technological solutions can be challenging for any organization. But Bharat Forge was determined to make the change as smoothly as possible. After an implementation phase, which included training key users, Creaform’s solutions were ready to be put to the test. The first step was to develop relevant 3D measurement programs and analyze performance levels.

One huge breakthrough was training the rest of the staff. “We were impressed with how quickly our employees adapted to the new system,” Heimbeck says. “Once our power users were trained, other team members who were to use 3D scanners and software as part of our workflows were trained in just a few days.” 

This marked a major shift for the company. Where previously only a select few specialists could operate the company’s former tactile system, employees across different departments can now contribute to the 3D measurement process. “It was a very short training period, given the complexity of our products,” Heimbeck says. “This allowed us to assign many more people to added-value work, boosting our overall efficiency.”

The HandyPROBE arm-free portable probing system generates accurate results right on the shop floor.

Substantial time savings, increased efficiency, and satisfied customers

The impact of Creaform’s 3D metrology solution was felt almost immediately. The time needed to measure each component dropped dramatically, saving up to 75% of the time previously spent on 3D measurement tasks. “We used to spend up to two hours measuring a single complex component,” Heimbeck says. “Now, that time has been reduced by 1.5 hours per task. It’s a game-changer for our production process.”

Because Creaform’s solutions were more straightforward, the company no longer depended on a small group of highly trained technicians. “With Creaform, five times as many employees can now be deployed for measuring,” says Heimbeck. “We plan to expand this further with additional training, allowing us to take on more projects across multiple shifts.”

Bharat Forge also fulfilled customer expectations. A case in point: One specific project involved measuring an aluminum chassis component with free-form surfaces for a renowned OEM. The customer expected optical measurement for initial samples and tests during series production—a task that would have been nearly impossible with legacy systems.

Heimbeck says, “Creaform 3D scanners and integrated software allowed us to meet the customer’s exact specifications while saving time and improving accuracy. It’s been crucial in maintaining our relationships and securing follow-up orders.” 

A great advantage of Creaform’s 3D measurement solutions is its integration of various software programs.

The company is now looking to expand the use of Creaform’s 3D metrology solutions across other areas of the company. Upcoming projects include measuring a 5-meter-diameter gear wheel for a forging press and other large machine assemblies.

“Our work with Creaform has fundamentally changed how we approach 3D measurement tasks,” Heimbeck says. “We’re excited to explore even more possibilities as we integrate these technologies into other parts of our business.”

Published Jan. 27, 2025, by Creaform.