A metal additively manufactured axial compressor was brought to Formtech to confirm that the printed geometry matched its source CAD model before further machining and balancing.

Working from a high-resolution 3D laser scan of the as-printed part, we aligned the captured mesh to the nominal CAD model and computed a full surface deviation analysis. The resulting colour map quantifies form error across every blade and the central hub, immediately highlighting regions of concern, and allowing adaptive machining strategies to produce a truly accurate part.

The client received a documented deviation report with per-region tolerances — objective evidence that the component met design intent, and a clear record for their quality file.

Formtech was engaged to verify a large composite tooling mould before it entered production. Tooling at this scale is prone to warping during manufacture, and even small deviations carry through to every part later pulled from the mould.

We captured the full mould surface on site using infrared 3D scanning, then compared the scan against the intended nominal geometry. The deviation analysis revealed where the surface had moved relative to design, mapping warping and manufacturing error across the whole tool.

Formtech delivered a clear deviation report giving the manufacturer a precise, measured picture of form error — enough to make an informed call on rework before committing the tool to production.

Following a suspected structural incident, Formtech was engaged to determine whether the chassis of a large rigid-frame mining haul truck had sustained deformation — objective, measurement-based evidence to support the client’s repair and insurance assessment.

The complete vehicle was captured on site with a handheld SLAM LiDAR scanner — no disassembly, no fixed instrument setups, and no interruption beyond the scan itself. From the registered point cloud we derived a reference axis through the front swing-arm pivot and compared it against the centre-line of the tipper-body eyelet bores. In an undeformed chassis these axes hold a known, repeatable geometric relationship, so any departure between them is direct evidence of frame bending or distortion.

The comparison measured a 31.8 mm longitudinal and 29.8 mm vertical departure between the axes — clear, quantified confirmation of chassis deformation. The client received a documented technical inspection report setting out the methodology, results and figures: the measurement evidence needed to make an informed repair-or-write-off call. The same approach works for dump bodies, excavator booms, dragline components and other large mining equipment where alignment matters and downtime is expensive.