Sensor Technology How 3D Sensors Boost Precision and Cost Efficiency in the Industry

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3D sensors, with their precise object detection, can optimize manufacturing processes and increase efficiency in numerous applications. This article highlights details on various areas of application.

In recent years, sensors have become not only more accurate but also more cost-efficient due to new technological advancements, and they can also be more easily integrated into existing systems. Christian Reinwald, Head of Product Management & Marketing at Reichelt Elektronik, highlights the areas where new opportunities are emerging for the industry.

The Different 3D Sensor Technologies

As diverse as their applications are the technologies on which modern 3D sensors are based. These result in different sensor types that vary in terms of accuracy, range, or processing speed, making them suitable for various applications.

One of the most well-known sensor technologies is LiDAR (Light Detection and Ranging), which measures distances by emitting laser beams to generate precise depth maps. It operates on the same principles as radar, but instead of using microwaves, it utilizes reflected laser pulses as measurement values. Due to its ability to measure distances with exceptional accuracy, LiDAR is frequently used for environment sensing in robotics, autonomous vehicles, and the creation of high-resolution 2D and 3D maps.

Time-of-Flight (ToF) sensors measure distances by determining the travel time of a light pulse to an object and back. They are compact while being exceptionally fast and precise. This makes them versatile for use in smartphones, augmented reality applications, industrial real-time systems, and robotics.

Stereo camera systems, on the other hand, use two or more cameras that determine the depth of objects through triangulation, similar to the human eye. At the same time, they also provide high-resolution image data—an advantage in areas such as quality control and visual inspection.

Structured light systems, on the other hand, project a defined pattern (e.g., grid or dots) onto a surface and analyze the distortion of the pattern to reconstruct the surface structure in three dimensions. This technology is primarily used in 3D measurement, optical scanners, and gesture recognition.

More Precision, Fewer Costs

Using these various technologies, sensors have made significant advancements in recent years. Not only do they offer clear improvements in capabilities such as depth resolution, but they are also becoming smaller, more powerful, and more energy-efficient. This makes them increasingly suitable for industrial applications.

The scaling of mass production is also an important factor: due to the rapidly growing market—driven by advancements in automation technology and robotics—many components can now be manufactured cost-effectively in large quantities. As a result, sensor technologies like Time-of-Flight or structured light systems, which were previously used only in specialized applications, are now economically feasible even in low-cost products.

Industrial Application

Even today, there are successful application examples showing how 3D sensors with their diverse capabilities can unlock new fields of application. They bring significant advantages, particularly in robotics, as evidenced by new gripping and placing mechanisms. What seems simple for humans—identifying, picking up, and relocating an object—was impossible for robots for a long time. Thanks to 3D sensing, modern robots can now perceive their environment in real time, recognize objects, and handle or process them—even if they fall randomly onto a conveyor belt and thus arrive in an unstructured position at the robot.

Another important application area is quality assurance and defect detection. 3D sensors are used here for highly precise measurement of components to detect deviations from the target dimensions at an early stage. By capturing the surface structure, even the smallest defects such as cracks, deformations, or wear can be identified, often contactlessly and in real time during the production process. This helps reduce scrap rates and sustainably improve product quality.

3D sensors can also provide valuable services in logistics. By enabling automated inventory tracking and monitoring—via mobile robots or drones—storage areas and shelves can be scanned in three dimensions. This allows for precise stocktaking without manual effort. Additionally, warehouse operations can be organized more efficiently with their assistance.

Great Potential for the Future

Looking ahead, the potential of 3D sensor technology is far from exhausted. New generations of sensors are already being developed in research, such as quantum sensors, which promise even higher resolution and sensitivity. At the same time, new application fields outside traditional industrial environments are emerging—for example, in smart cities, where 3D sensors could be used for traffic monitoring or building management.

Another pioneering field is human-robot collaboration, where 3D sensors ensure safe and precise interactions. 3D sensors are thus becoming central components that not only optimize current industrial processes but also significantly shape future developments. (mk)