Through recent advancements in high-density dimensional (HDD) measurement technologies, such as 3D laser scanners, data-sets consisting of an almost complete representation of a manufactured part's geometry can now be obtained. While HDD data measurement devices have traditionally been used in reverse engineering application, they are beginning to be applied as in-line measurement devices. Unfortunately, appropriate quality control (QC) techniques have yet to be developed to take full advantage of this new data-rich environment and for the most part rely on extracting discrete key product characteristics (KPCs) for analysis. In order to maximize the potential of HDD measurement technologies requires a new quality paradigm. Specifically, when presented with HDD data, quality should not only be assessed by discrete KPCs but should consider the entire part being produced, anything less results in valuable data being wasted. This dissertation addresses the need for adapting current techniques and developing new approaches for the use of HDD data in manufacturing systems to increase overall quality control (QC) capabilities. Specifically, this research effort focuses on the use of HDD data for 1) Developing a framework for self-correcting compliant assembly systems, 2) Using statistical process control to detect process shifts through part surfaces, and 3) Performing automated part inspection for non-feature based faults. The overarching goal of this research is to identify how HDD data can be used within these three research focus areas to increase QC capabilities while following the principles of the aforementioned new quality paradigm. / Ph. D.

This study project looks at how metrology and inspection methods have advanced inside machining processes to improve production efficiency, accuracy, and precision. The study includes an extensive examination of the literature, observational research, and critical analysis to provide insights into the possibilities, difficulties, and practices that exist in the sector today. The literature review charts the development of metrology from manual measurement techniques to highly automated systems, emphasizing the crucial roles that optical inspection systems and coordinate measuring machines (CMMs) play in contemporary production. Modern inspection technologies, including as non-contact techniques and laser scanning, are also discussed, along with the difficulties in combining metrology data with digital production systems. Observational research offers direct knowledge of how metrology and inspection techniques are used in real-world industrial settings. Alongside difficulties including operator skill levels and equipment calibration, the usage of portable measuring tools, CMMs, and optical inspection systems for assessing surface finish and dimensional correctness is noted. Findings study points to growing problems such the requirement for experienced operators and operational unpredictability in machining processes, as well as the increasing integration of metrology and inspection methods into machining processes. But there are also prospects for development, with an emphasis on the ability to increase efficiency and quality control, via Industry 4.0 projects and additive manufacturing technology. All things considered, this study project clarifies the crucial function metrology and inspection methods play in contemporary manufacturing and provides guidance for enhancing quality assurance and machining process efficiency.