Accelerating digital quality control with advanced 3D scanning technology

Alpha Manufacturing, part of The HEX Group, is a Staffordshire-based sheet metal fabrication specialist with over 40 years of experience. While historically serving in-house group brands like Bri-Stor Systems, Alpha Manufacturing has transformed into a diversified subcontractor delivering full-service manufacturing, from CNC machining to sub-assembly and integration, for a wide external client base. Continuous investment has led to a highly advanced shop floor with state-of-the-art laser cutting, bending, and machinery, with a focus on digital transformation in quality control.

Alpha recognised a growing need for more robust, data-driven inspection processes, particularly when serving customers with complex, high-precision fabrication requirements. The business sought to move beyond traditional methods and adopt a system capable of capturing accurate, repeatable data for both customer assurance and internal quality development. The company contacted Measurement Solutions Ltd (MSL).

The introduction of the Creaform MetraSCAN 3D is shaping how quality control is approached across the business. Initial use focused on a key customer project, while the company lays foundations to extend scanning into multiple stages of production where high precision and repeatability are critical. The system’s flexibility suits the varied workload and diverse customer needs.

Application areas include inspection of large fabrications, dimensional comparison to CAD models, data capture for repeat and long-term runs, and quality assurance touchpoints at multiple production stages, such as post-punch and post-weld operations.

Alpha Manufacturing’s adoption of the MetraSCAN has come with practical considerations that have provided insights, highlighting areas to strengthen processes and ensure long-term success. From team structure to infrastructure planning, the company is taking a thoughtful, phased integration approach.

Internal champions are being developed to embed the MetraSCAN into daily workflows. A dedicated scanning area is under development to house the system in a controlled, optimised environment, ensuring consistency and operational flow. Reporting protocols are being formalised, and data outputs will be integrated across departments. The team is shifting from reactive checks to proactive process control, reflecting a meaningful, sustainable approach to technology adoption.

Alpha Manufacturing selected the Creaform MetraSCAN 3D for flexibility, precision and suitability for varied subcontracting demands. Its metrology-grade accuracy of up to 0.025 mm enables high-precision analysis, while high-speed scanning captures millions of points per second, up to 25 times faster than traditional methods, reports MSL. Lightweight and portable, it can be deployed across the shop floor.

Intelligent tracking ensures accuracy even if the part or scanner moves, and quick set up reduces downtime. This versatility makes it suitable for projects ranging from small intricate parts to large assemblies.

MetraSCAN 3D is among the most accurate combined scanning and probing solutions available. Creaform’s TRUaccuracy technology ensures precise measurements regardless of operator skill or environment, including instability, vibration or thermal variation. The handheld system scans up to 1.8 million points per second, with dynamic referencing, auto alignment, the ability to scan almost any surface, portability, a 16.6m³ volume and 0.025 mm resolution.

Although early in its journey, Alpha Manufacturing is already seeing the positive impact of 3D scanning. The MetraSCAN helps respond confidently to customer demands while setting the stage for process improvements. With a clear roadmap, benefits are expected to grow as scanning becomes embedded in day-to-day operations.

Early outcomes include improved confidence in quality for key customers, a roadmap toward full process integration, plans for a digital library of scanning templates to support high-volume repeat work, reduced reliance on manual measurement and end-of-line inspection, and growing internal alignment around data-driven quality assurance.

As Greg Howell from Business Improvement at Alpha Manufacturing explains: “We’re still early into our journey with the MetraSCAN, but the vision is clear. We want every repeat job scanned, compared against programmed criteria, and quality-assured from the first part. The technology’s potential is huge; it’s just about getting the right people and structure in place to unlock it.”

By the end of 2026, Alpha Manufacturing expects a dedicated scanning zone operational, alongside an established process for integrating 3D scanning across production stages. A phased rollout of repeat-part scanning templates will follow, ensuring efficiency and traceability for long-term, high-frequency orders.

Long term, the MetraSCAN will support the company’s vision of transforming inspection from a final checkpoint into an in-process assurance tool, strengthening customer partnerships and enabling even higher quality standards.