Hexagon transforms tube and wire manufacturing productivity with turnkey optical inspection cell and effortless CNC bending machine integration
Hexagon’s Manufacturing Intelligence division has launched the 2025 TubeInspect system, a non-contact optical quality inspection solution that delivers reliable measurement results in seconds and helps manufacturers streamline tube and wire workflows. Building on mature metrology device and software heritage, the next-generation solution integrates advanced optical measurement with effortless workflow automation, setting a new benchmark for production efficiency and a rapid return on investment (ROI).
In an increasingly competitive manufacturing landscape, tube and wire manufacturers are challenged by increased part complexity and customisation with shrinking margins – particularly for sectors such as eMobility, where traditional inspection methods have become a bottleneck. Outdated methods using mechanical gauges and manual corrections not only slow down production but also introduce inconsistencies that impact quality and cause waste. Hexagon’s 2025 TubeInspect has been re-engineered to overcome these challenges, providing:
- High speed optical measurement delivers precise, non-contact assessments in seconds, ensuring that every component meets tight tolerances in any environment. The new system is engineered to deliver repeatable accuracy even in oily, dusty, or high temperature environments thanks to advanced temperature compensation and ISO 17025-certified calibration.
- Seamless process integration with Hexagon’s BendingStudio XT software allows for closed-loop manufacturing processes, with real-time correction data sent directly to CNC bending machines and built-in interfaces for over 45 leading bending machine tool brands worldwide. Using these intelligent correction capabilities, manufacturers can achieve perfect parts within 1-3 automated correction loops, reducing waste and ensuring consistency.
- Automated workflows reduce the manual inspection times and enable rapid validation of part tolerances, minimising downtime and driving efficiency across production lines. Integrated features such as one-button operation, automatic drill hole measurement, on-device HMI (Human-Machine Interface) with a simplified display of measurement results on an integrated screen and remote asset monitoring enhance operational efficiency and minimise manual intervention.
- Easy and flexible deployment because shopfloor operators can easily adopt its workflows, it minimises any disruption to production and quickly boosts manufacturing productivity. A fast, automated setup process initiates the measurement cell so it is ready to use in minutes. Once deployed, flexible inspection capabilities are able of handling multiple part types in a single workflow, eliminating the need for expensive mechanical gauges and further cutting quality inspection time.
The 2025 TubeInspect is engineered to transform how tube and wire quality is managed on the shop floor, unlocking operational efficiencies in multiple industry applications from automotive exhaust and brake line inspection to safety-critical aerospace and energy plant component quality control. Manufacturers of electric and hybrid vehicle components like motor hairpins and busbars can deploy the turnkey system to ensure high-performance and precise production standards, helping to maintain competitiveness in a rapidly evolving market.
"With 2025 TubeInspect, we have significantly enhanced both the speed and accuracy of tube and wire manufacturing processes in any production environment, and integrated our powerful BendingStudio XT software," said Dr. Christoph Dold, Hexagon’s Senior Product Manager. "It doesn’t matter what bending machine you have – with our solution you can achieve perfect parts in just a few correction loops, delivering the highest standards of quality and productivity. We are seeing rapid ROI for existing customers, and for those that are still struggling with more manual processes and generic quality inspection technologies, it can be transformational.”
The new 2025 TubeInspect 35 and TubeInspect 37 series, fully integrated with BendingStudio XT, is available for order with Hi-Tech Metrology now.