Mursalin Pathan – Content Writer
Pune, India | September 22, 2025
Bruker Alicona has introduced SensorX, a major advancement in optical metrology for automated production lines. Unveiled at EMO 2025 in Hanover, this compact, OEM-ready 3D measurement system enables precise surface and form analysis directly within the manufacturing process.
To begin with, SensorX is a fully validated, plug-and-play solution designed for easy integration into third-party systems. It uses Bruker Alicona’s core technologies, including Advanced Focus Variation, Focus Probing, and Vertical Focus Probing. Together, these deliver accurate, high-resolution 3D measurements—even for complex geometries. One of the standout capabilities of SensorX is its ability to measure steep flanks over 90 degrees. Consequently, it can inspect sharp edges, freeform surfaces, and fine structures. Moreover, it performs these measurements without contact or the need for sample preparation, making it ideal for in-process inspections.
Additionally, SensorX uses Vertical Focus Probing to scan vertical and undercut features—areas that traditional tools often miss. Its coaxial illumination, on the other hand, ensures consistent results even under challenging lighting or surface conditions. As a result, SensorX is both resilient and adaptable to demanding production environments.
Importantly, the team built the system from the ground up with OEM integration in mind. For example, at EMO 2025, Bruker Alicona demonstrated its operating inside Nagel Technologies’ NaPrep cell—an automated edge preparation system. This cell processes tools like drills, taps, and inserts. Within this setup, SensorX performed live measurements, tracked tool wear, and supported closed-loop control. Consequently, the production process became fully autonomous and traceable, leading to notable improvements in both efficiency and consistency.
In a broader context, SensorX represents a major shift in how manufacturers approach metrology. Previously, quality checks were often performed offline, requiring manual handling and resulting in delayed feedback. This, in turn, created inefficiencies and increased the risk of errors. Now, SensorX addresses these challenges by embedding precision measurement directly into the production line. As a result, manufacturers can detect deviations in real time, make immediate adjustments, and minimize waste through proactive control.
Furthermore, beyond its advanced optical capabilities, SensorX delivers several practical benefits for manufacturers. It significantly boosts throughput by eliminating the downtime caused by offline inspections. It also helps maintain consistent surface quality and tool performance by enabling tighter control over edge preparation. Most importantly, it merges traceability with automation, thereby paving the way for smarter, data-driven manufacturing environments.
SensorX also builds on Bruker Alicona’s long-standing history of metrology innovation. While it follows the path set by earlier systems like InfiniteFocus and FocusX, SensorX goes further. Specifically, it brings those high-resolution capabilities into fully automated workflows. This, in turn, empowers OEMs and integrators to create more intelligent and flexible manufacturing systems.
Moreover, industries that demand high precision—such as aerospace, automotive, medical devices, and high-performance tooling—stand to benefit significantly. For instance, tool manufacturers can guarantee consistent edge rounding. Similarly, medical device companies can validate surface geometries during assembly, all without slowing down production.
By bridging the gap between inspection and production, SensorX enables better process control, enhanced product quality, and greater operational efficiency. Bruker Alicona has, therefore, responded to the growing demand for inline, high-precision metrology with a solution that is not only accurate and reliable but also fully industrial-ready.
In conclusion, as the manufacturing sector continues to embrace automation and digital transformation, SensorX arrives at precisely the right time. It redefines metrology—from a passive checkpoint to an active driver of productivity. With this launch, Bruker Alicona is not just offering a new tool but is ushering in a new era of smart manufacturing.
