Coating thickness measurement for industrial processes with Enovasense PS
Non-destructive coating thickness measurement for in-line quality assurance
Why is layer thickness measured?
Every micrometer counts—whether for corrosion protection, product performance, or regulatory compliance. Unreliable layer thickness measurements lead to costly scrap, quality defects, or safety risks, while precise control ensures durability, efficiency, and customer confidence. In many industries—from automotive and aerospace to medical technology—real-time measurement is the key to error-free production and ensures competitive advantages.
The Enovasense Point Sensor (PS) sets new standards in industrial quality assurance with its patented laser photothermal technology. The Point Sensor enables non-contact and non-destructive in-line thickness measurement of all coating types on any substrate. The system is integrated directly into production lines and provides 100% in-line inspection with real-time process feedback. The Enovasense PS easily handles challenging conditions such as wet surfaces, moving parts, or hard-to-reach components.
Measurement of coating thickness: your advantages with Enovasense point sensor
Lightweight photothermal radiometry sensor with small footprint
Weighing as little as 150 g and measuring 35 x 35 x 64 mm, the Enovasense PS sensor heads are the ideal lightweight, ultra-compact photothermal sensors for inline inspection applications. Each sensor head comes with a separate controller and can be integrated into almost any small, tight space. The cable between the sensor head and the controller can be up to 20 meters in length. What's more, the probe contains no moving parts, which enables maintenance-free integration.
High-precision measurement of any coating layer
Precise and stable thickness measurements are possible on any kind of coating and substrate materials – diffusive or reflective, flat or curved, rough or polished – and on any surface, e.g. mirrored, unfinished metal, ceramic or adhesive surfaces. The range of thicknesses measurable is also incomparable – from nanometers to millimeters with a measurement stability that stays submicrometric-stable for years.
Highly versatile point sensor series
The two sizes of probes - the compact T033 and the ultra-compact T060 - each have variants with angled laser beam to measure perpendicularly to the head length. Moreover, various optical front lenses enable a wide range of working distances and laser spot diameters from 0.3 mm to 12 mm. A specific high-distance objective can be placed on the T033 measuring head to increase the working distance to 200 mm and the distance tolerance to ±50 mm.
Easy integration in nearly all industrial environments
This non-destructive, non-radiative technology allows measurements with low alignment operations. With an alignment tolerance of up to ±10 mm around the nominal distance and an angle tolerance of up to ±50°, the Enovasense point sensor offers uniquely easy integrability. The sensor displays a high degree of stability to vibrations and changes in the part curvature and shape. The sensor can measure parts at very high temperatures and is suitable for room temperatures up to +50°C.
Industries that rely on Enovasense point sensors
Proven applications in coating thickness measurement:
Automotive: Zinc-flake coating on brake discs, laser cladding on brake discs, UV paint on prismatic battery cells, coating thickness control on bipolar plates, E-coat thickness measurement on large and complex automotive parts, fuel cell coatings
Aerospace: Thickness measurement of paint-on composites and critical paint-on engine parts, aluminum anodizing, thickness inspection of thermally sprayed coatings, aerospace fastening systems, inorganic coatings on aircraft engines
Medical: Coatings on orthopedic implants
Metalworking: Coil-coating inline thickness measurement
Semiconductors: conformal coatings on pcbs
Technical data
- Measuring range : 0.01 µm – 1000 µm*
- Measurement repeatability: < 1% of the measured thickness*
- Measurements per second: 1 Hz up to up 100 Hz
- Enovasense PS interface: Ethernet
*Depends on the coating material
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