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Transform Your Coating Process

Industrial process control

Stop discovering coating defects after the oven

PaintChecker gives industrial coating teams earlier visibility into coating thickness, before curing locks in the cost. Reduce rework. Improve first-pass yield.

Move from reactive inspection to proactive process control.

PROBLEM

​The real problem isn't measuring coating thickness.
It's when you find the variation.

You find out the coating is wrong too late, after curing,
when correction is already expensive. 

You find out after the oven, when it's too late to fix.

Contact and eddy-current gauges only read once the coating has cured, 30 minutes to hours after the part was sprayed. By then the powder, the energy, and the production time are already spent. Correction is no longer simple. It's rework.

One wrong setting runs through a whole batch.

A single drifting gun or a new powder pushes part after part out of tolerance, and nobody sees it until the trend shows up downstream. You don't discover one bad part. You discover everything that inherited the same mistake, after you've already paid to coat and bake all of it.

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The places that matter most are the ones you can't measure.

Edges, curves, recesses, weld seams, undercuts, the exact spots where thickness varies and defects hide, are where contact gauges struggle or can't reach at all. A flat test panel beside the part never tells you the truth about the part itself.

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The hidden cost of finding out too late

You don't find out the coating is wrong until the part is already out of the oven. Cured. Cooled. Done. And by then, the decision has already been made for you. Below is what it actually costs, in the words of the people living it every day

"We only knew after baking, and by then it was already too late."

"You can't touch fresh powder, so we were flying blind until final inspection."

"The complicated areas are exactly the ones we couldn't measure."

"Recoating an XXL part means sending a ton of steel through the entire line again."

"So we just sprayed extra, to be safe."

"One gun drifts out of adjustment and nobody can tell which one."

"Every audit, the paperwork got harder to defend."

"New staff had no way to know if their own work was any good."

SOLUTION

Measure earlier, control better

The value is not simply that PaintChecker measures without contact. 
It gives you information while you can still act.

Move the measurement point forward

The traditional process:
SPRAY → CURE → MEASURE → ❌ FIND THE PROBLEM
By then, correction is no longer simple.

Instead of waiting for the coating to cure, PaintChecker lets you measure thickness directly after application.

A better process:
SPRAY → PAINTCHECKER ✓ → CORRECT → CURE

One simple change in the process gives you a much earlier chance to get the coating right.
Before the result becomes permanent.

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Fix Thickness Problems While They Are Still Fixable.

Measure on soft powder and wet paint before curing and without contact.

So your team can detect thickness variation earlier, correct the process faster, and avoid discovering an expensive problem when the part comes out of the oven.

PaintChecker helps turn coating thickness measurement from a final inspection step into a tool for process control.

From checking what happened…
…to controlling what happens next.

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Measure before cure, on critical areas

PaintChecker measures where it matters.

Measure before curing

Catch Thickness Variation Before It Becomes Rework.

PaintChecker measures freshly applied powder and wet coatings without touching the surface.

Your team can verify thickness immediately after application instead of waiting for the curing cycle to finish.

That creates faster feedback during:
* Line setup
* Colour changes
* New coating trials
* Spray-gun adjustment
* Robot programming
* Manual coating
* Process optimisation
* Production quality checks

When the process begins to drift, your team can respond sooner.
* Less guessing.
* Less waiting.
* More control over what enters the oven.

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Measure critical area

The Most Important Measurement Point Is Rarely the Easiest One.

Measure Where Thickness Actually Varies

Flat test panels can be useful.
But real production parts have:
* Edges
* Curves
* Corners
* Recesses
* Creases
* Narrow surfaces
* Complex geometries

And these are often exactly where coating thickness becomes difficult to control.

Because PaintChecker measures without contact, your team can inspect sensitive uncured coatings and critical areas where conventional contact gauges may be difficult to use.

Measure the real component.
Not only the convenient place where a gauge happens to fit.

Identify thin spots, excessive build-up and local thickness variation where coating performance is actually at risk.

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PaintChecker products

Contactless measurement of uncured powder, wet paint, and cured coatings.

PaintChecker Mobile

Flexible, contactless measurement for process engineers, quality teams and paint shop personnel.

Ideal for:
* Process optimisation
* Troubleshooting
* Line setup
* Manual quality checks
* New product introduction
* Critical-area measurement

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PaintChecker Industrial

Automated coating thickness measurement for production systems, robotic cells and inline applications.

Designed for manufacturers that want continuous process visibility and automated quality control.

Ideal for:
* Automated inspection
* Robotic measurement
Inline monitoring
* Process documentation
* High-volume production
* Smart manufacturing systems

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PaintChecker mobile measure on car rim
00:34
Cube Sensor on Model-Robot
01:25
PaintChecker Mobile Pen on tractor hydraulics
01:38
PaintChecker Industrial Tube HP checks inner coating of pressure vessel
01:04
Simultaneous test on neuralgic parts of an enclosure
00:28

CASE STUDY

Proven in production

What actually happened on the floor

Powder coating XXL part — "Coating thickness measurements with PaintChecker save more than 1000 EUR per scrap part."

On the oversized line, a loading bridge close to a ton hangs at an angle, 250 mm from the gun at the top, over 400 mm at the bottom. In graphite grey (RAL 7024), a massively undercoated part looks flawless to the naked eye. The old way, you'd learn the truth only after the oven, and then that ton of steel travels the entire line a second time, roughly €1,000 per part, gone. Now the operator verifies the manual touch-up zones and weld seams before the part reaches the oven. The plant reports undercoating virtually eliminated, a much more stable process, and confirms the investment was already paid back on avoided re-runs alone, even with 16 to 20 automatic guns and part-geometry scanners already in place.

Battery cell insulation — Due to the tiny, point-shaped measuring spot, even the smallest components can be precisely measured.

The photothermal measurement method provides a fast and convenient way to determine coating thickness with accurate, reproducible result. Ultra-thin insulation coating on aluminum battery housings is safety-critical, too thick or too thin and the cell risks failure. The line had extreme space constraints and short cycle times, demanding non-contact measurement at multiple points at once. Compact photothermal sensors, only 40 mm deep and 150 g, were co-developed and integrated into the PLC-controlled line in four months. The result: a standard deviation below 0.5 µm across 2,900 continuous measurements, real-time non-destructive validation of every cell, feeding battery safety and throughput at the same time.

High-speed automotive parts — 100% inline measurement at 150 parts a minute.

Parking-sensor caps have brutally narrow tolerances, a few microns too thick and the ultrasonic membrane can't oscillate, so the distance reading fails; too thin and corrosion protection goes. Parts are tiny (roughly 20 mm diameter), curved, and densely packed, with under 0.5 seconds per measurement and no room to spare. The system measures the powder while it's still soft, inline, at about 150 parts per minute, every value logged to the PLC and central database and shown on line-side monitors. Operators see trends drift toward the limits and correct before anything escapes. It has run in continuous multi-shift production for over 15 years on a single circuit-board replacement.

Rail vehicle coating — the early process control thanks to the non-contact layer thickness measurement is extremely valuable because the measurement results can be evaluated and assessed very early

A powderer finishes a large rail component and lifts the 50-gram sensor to the back face, the "averted" side that always ran thin. Three LED dots line up, trigger pressed, and in under a second the reading comes back low. He adjusts the gun and re-sprays the still-soft powder right there. That part enters the oven correct. Before, that low reading only appeared after baking and cooling, by which point every part behind the booth had inherited the same defect. Now the mass-scrap event that used to define a bad day simply doesn't happen. The plant runs dozens of daily checks with minimal effort, fully aligned to DB and QIB documentation standards, and operators control quality at the booth instead of firefighting at the oven exit.

High-mix powder coating — Rework? That is a thing of the past.

With PaintChecker mobile, we get to target much faster to meet our quality standard. A plant runs over 1,000 different coatings a year, from small medical housings to 7-meter structures, across automatic 8-gun booths, manual booths, and a sample booth, with constant color changes. Every changeover was a fresh chance to run out of tolerance, and contact gauges only confirmed it 30 minutes to hours later. The mobile system measures 20 to 250 µm on any color or material, steel, aluminum, medical parts, on a single factory calibration, no recalibration per surface. Operators fine-tune at the booth exit, skip sampling steps, start production faster, and reach for the parts, edges, and curves that used to be blind spots.

R&D lab — Leatherette: Precise testing of clear coat on plastic film

An application chemist develops a clear anti-creak coating around 15 µm on soft grained leatherette. For years the only "measurement" was to coat a metal dummy alongside and hope the number transferred, a contact probe just deforms the soft surface and lies. Thickness scatter ran over 80 µm, and parts squeaked with no clear cause. Now she measures the real substrate directly, correlates true film build to the stick-slip test in front of her, and pins down the exact thickness window where the squeak disappears. Days of indirect trial-and-error collapse into an afternoon of real data

Wet paint on chrome — “ Checking the coating thickness distribution in the wet state while programming the line, significantly increases the quality".

A premium finishing plant runs 20,000+ chrome sanitary parts a week plus automotive trim and consumer electronics. Contact and eddy-current gauges failed completely on chrome, so thickness could only be checked after curing, sometimes by destructively grinding the part. A competitor device was aborted mid-test by the production team. PaintChecker was the only system that reliably measured wet film on chrome in series production. Painters stopped over-spraying "just in case," cut material consumption, and programming engineers finally saw real-time film distribution during robot path creation, turning trial-and-error into confirmed uniformity before the run.

Why Optisense

Customers do not buy microns.
They buy predictable production outcomes

With PaintChecker, you own not only a measuring equipment.

You are getting earlier visibility, better process decisions,

reduced uncertainty, and greater confidence in coating quality.

See it in your own part

Stop paying for rework after the oven.

Find out what it's costing you, before the oven decides. 

Test PaintChecker on your own parts and powder, your own conditions.

A feasibility test on your production reality.

We respond to you individually. Your information is kept confidential.

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