Thickness Measurement Challenge Success Stories

Multi-layer Film Thickness Measurement Used on a Diabetic Test Strip: Lumetrics' OptiGauge Helps Customer Produce Top Quality Medical Device Product

measure thin films, film thickness measurementThe OptiGauge doesn't just provide thickness measurements for medical devices, it's also used by a diverse set of customers to provide online thickness measurement for coatings, thin films, and multi-layer films.

A Lumetrics customer needed the capabilities of the OptiGauge to provide critical thickness measurements of a 5 layer film used in a diabetic test strip. Used on line with 8 probes, a single OptiGauge provided measurements of adhesive in the wet state, after it left the drying oven, and was in its final 5 layer assembly.

This provided an essential view of the complete production process that enabled the film customer to fine tune their methods and manufacture materials in which thickness measurement is a selling feature and not a problem. In a recent call with the film manufacturer and the end user, they praised the quality of the film they received, thanks to the OptiGauge, were able to tighten their tolerances on the final product, thereby providing a superior product to the end user.

Tubing Thickness Measurement: Lumetrics Helped a Medical Device Manufacturer Find and Solve Problem in Production Process, and Speed Product to Market.

tubing thickness measurement, medical tubing inspectionTESco Associates Incorporated, a specialty contract manufacturer for bio-absorbable medical implants was installing a new production system to produce tubing with extremely close tolerances. Thickness measurement of the walls of the tube was a critical measurement. Lumetrics' OptiGauge, initially intended to be a QC instrument for production, was used to provide very precise dimensions and geometry of the tubing during development. This enabled TESco to trace down exactly where the problems were in the equipment and process, dramatically reducing the time to produce product that met their customer's specifications. The net result was a drastically decreased time from startup to fine-tuning, and reduced the time to produce qualified product from 4-6 months to just weeks.

A Success Story in Medical Device Inspection: Medical Balloon Thickness Measurement

medical device, medical balloon measurementFor one Lumetrics customer the thickness measurement challenge was how to measure an extremely small dipped silicone balloon. This project required the OptiGauge because touch gauges could not accurately measure the balloon either on the dipping mandrel or when the balloon was removed from the mandrel. The OptiGauge could measure thickness in either case, and because it could, the customer was able to understand and perfect the balloon molding process. In this case thickness measurement gave the customer the ability to produce a new medical device by understanding and modifying the process of making it. The customer said the OptiGauge was critical to his ability to make that product.


In these days of complex structures of everything from medical devices to food packaging, thickness measurement challenges continuously arise. Thickness measurement can be important for a number of reasons. Lumetrics' thickness measurement systems can help your process:

  • Maintain uniform thickness in multi-layer films, thin films, and coatings
  • Reduce the need to over-engineer product packaging by 20% and prevent wasting expensive product..
  • Help your operation produce a quality product that meets safety standards, reducing the possibility of costly re-calls
  • Provide accurate, real-time measurements while the product is being manufactured, reducing time to market.

We've worked with customers who've used outdated and unreliable inspection methods- who then purchased our thickness measurement systems and not only saw a significant reduction of waste, but a smoother process, better product, and of course a dramatic increase in their profit margin.

No matter what your thickness measurement challenge, call Lumetrics and consult with our experts to see if there is an OptiGauge solution right for you.


film thickness measurement, thin films

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