Rubber presents a challenge for optical-based measurement sensors. By nature, the black surface is difficult to capture reliable data from and accurately measure. This challenge is often intensified by the complex shapes into which rubber derivatives are extruded or molded.

As a solution to this challenge, 3D laser sensor manufacturers have optimised the design of their sensors to successfully implement scanning and quality control functions for both in-process and final product inspection applications in rubber and tyre manufacturing.

3D laser scanning

Rubber material comes in two forms on the production line, either as fresh and uncured from an extruder or a calender, or as a finished product (e.g., vulcanised tyres). Non-contact 3D laser scanning offers the most practical solution for inspection of both of these rubber material types.

Here’s why:

1. The soft, gummy nature of the rubber makes contact-type measurement ineffective. This measurement approach is also too slow to keep up with the high-speeds of continuous web material production.

2. 2D sensors require complex lighting to see black-on-black contrast. In some applications the lighting is placed underneath the material (e.g., when measuring the width of a strip), and hot sticking rubber can contaminate the lights. In addition, 2D can’t produce measurements related to object geometry (i.e., 3D shape), which means they are unable to measure critical features such as object flatness, surface angles, or part volumes, and are limited to contrast-based inspection. This makes 2D sensors a poor solution for scanning complex shape-based features on dark surfaces, or for operation in low lighting conditions.

          3. In comparison, 3D laser sensors are contrast invariants and generate high-resolution scans regardless of the material or lighting conditions. They also capture the complete 3D geometry of the scan target, including critical depth measurements on surface features such as grooves in a tyre tread. 3D laser sensors are also able to achieve the high speeds required for continuous web material scanning.

Laser profile sensors provide an ideal solution to both in-process and final rubber and tyre measurement and quality control applications. Built-in measurement tools for strip positions, including multiple groove location and depth measurement monitoring with automated alignment enable engineers to configure setup parameters––without requiring any measurement software development.

In addition, the ability to store multiple geometry configurations in the sensor makes changes between different recipes quick and simple, which is critical in minimising downtime for operations that make model changes multiple times per shift.

Application examples

1. In-Process Inspection

Extrusion Profiling with High-Resolution Gocator® 2440 Laser Profiler

Extruding rubber in a specific shape makes up the tread portion of a tyre. Measurement of the extrusion profile is carried out in-process, correcting the extrusion parameters in real-time to maintain the required shape. Key measurement parameters include thickness, width, and profile. Another required sensor capability is monitoring the position of surface features, such as ridges, center lines, and edges.

Profiling these tread extrusions is done by using 3D laser sensors to scan across the extrusion, generating a profile to which built-in measurement tools and pass/fail decision-making logic can be applied.

In this example, two Gocator 2440 laser line profilers are used to measure the rubber web’s extrusion groove pattern, geometry, and location with an X resolution down to 13 microns. Gocator 2440 sensors are able to inspect multiple grooves in a single setup, and groove measurements are unaffected by changes in surface angle relative to the sensor.

Most importantly, Gocator 2440 sensors generate critical 3D height data for robust shape measurement. 2D solutions are limited to contrast-based inspection.

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3. Final tyre inspection

Tyre Sidewall Inspection with High-Speed Gocator 2530 Laser Profiler

Traditional methods for measuring tyre sidewalls for defects such as bulges and dents suffer from too many false rejects (i.e., classifying a good tyre as defective). Due to measurement system limitations, many manufacturers have no choice but to “oversensitise” their sidewall bulge and dent measurement systems, resulting in costly manual inspection requirements for all rejected tyres.

In fact, some measurement systems cannot even distinguish between bulges or dents. However, with state-of-the art laser measurement precision and advanced built-in software analysis, false positive rates can be substantially reduced and, in many cases, eliminated altogether.

Using a Gocator 2530 laser profiler the engineer is able to generate full surface point cloud geometry data in order to detect small defects (down to 28 microns X resolution) anywhere on the sidewall surface. The sensor also delivers complete scan, measurement, and control at 4 kHz, allowing engineers to meet stringent cycle time requirements––with no need for industrial PCs or external controllers.

In this configuration, two profile sensors are typically used, one for each sidewall (top and bottom buddy system). A third sensor is often used to monitor radial runout of the tread.

Leveraging 3D Laser Scanning and Inspection

Laser-based laser triangulation sensors meet the high speed and high resolution requirements for accurate rubber and tyre measurement. These sensors are used in a variety of in-process and final inspection applications, including extrusion profiling and tyre sidewall inspection.

Adding 3D laser sensors for automated quality control is vital to reducing scrap and rework, and improving final product quality by maintaining consistency throughout the tyre manufacturing process.

Courtesy of LMI Technologies www.lmi3d.com

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AI mobile data capture company Anyline has released the latest version of TireBuddy, a smartphone-based system for automotive tyre inspections. Version 1.8 introduces fully automated sidewall capture that removes human variability from data collection. The tool has already helped service teams achieve faster, more uniform inspections over the past year, leading to increased tyre sales and stronger customer trust.

The automated mechanism uses on-device guidance that evaluates each image against four criteria: full sidewall detection, sharpness, proper distance and angle and overall clarity. This real-time feedback minimises redo scans by guiding technicians to capture optimal images immediately. The system addresses common challenges in busy service bays where accuracy often suffers due to varying experience levels.

Standardisation of inspection quality is a primary benefit, as consistent results are achieved regardless of who holds the phone. This removes dependency on technician skill or training duration. New or seasonal staff can perform scans confidently from day one without extensive instruction. The automated capture now serves as the standard protocol for all inspections across locations and shifts.

Additional features include tyre mismatch alerts that flag size discrepancies, automated email reports to back-office systems and a redesigned results screen consolidating sidewall information and tread measurements. With hundreds of thousands of annual inspections, this update reinforces TireBuddy's role in modernising tyre service operations.

Lukas Kinigadner, CRO, Anyline, said, “A shop is only as consistent as its least experienced inspector. Automated sidewall capture gets every scan to the same standard, so teams can stop treating inspection quality as a variable.”

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Epson, a global leader in SCARA robot manufacturing, has unveiled its next-generation industrial robotics portfolio at Automation Expo Mumbai 2026. The newly introduced lineup features the high-end CX-A Series 6-axis robots, the LS-C Series SCARA robots, the RC+ 8.0 programming software and the advanced SafeSense safety technology, all designed to address diverse manufacturing applications such as pick-and-place, precision assembly, parts transfer and material handling.

The new offerings significantly expand Epson’s existing industrial robotics family, which already includes the 6-axis C-Series and SCARA T-Series and LS-Series models with payloads ranging from 3 to 20 kilogrammes. With the addition of the CX-A and LS-C Series, manufacturers across various sectors can achieve heightened productivity, flexibility and operational efficiency. The CX-A Series is engineered for complex tasks with a payload capacity of up to seven kilogrammes and a reach of 900 millimetres, available in IP67, cleanroom and ESD variants, while the LS-C Series provides a compact SCARA platform with a 50-kilogramme payload, a 1,000-millimetre reach and cycle times as fast as 0.298 seconds.

Complementing the hardware, the RC+ 8.0 software offers an integrated environment for programming, simulation and system management, facilitating faster automation deployment with support for Visual Studio and C++ development. Additional efficiency features include enhanced diagnostics, OPC UA, GUI builder and safety functions, alongside co-creation tools like Library Builder and RC+ Extension. Meanwhile, the SafeSense technology promotes safer human-robot collaboration by incorporating Safety Limited Speed and Safety Limited Position functions, which can potentially reduce the need for extensive safety fencing and thereby increase operational flexibility.

With over four decades of industrial robotics expertise and more than 200,000 robotic arms deployed globally, Epson continues to drive operational excellence for businesses. Attendees at Automation Expo Mumbai 2026 have the opportunity to view live demonstrations of these solutions and consult with Epson specialists about transforming their manufacturing operations.

Siva Kumar, Sr General Manager – Sales and Marketing, Epson India, said, "India is rapidly emerging as a global manufacturing hub, and automation will play a pivotal role in shaping its future. With our new industrial robot lineup and RC+ 8.0 platform, Epson is delivering the speed, precision and intelligence manufacturers need to compete in an increasingly dynamic marketplace. We remain committed to enabling businesses to accelerate automation adoption and build smarter, more agile and globally competitive manufacturing operations."

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A consortium of Fraunhofer institutes has reached a key milestone in the Technology Platform for Tire Abrasion and the Identification of its Emissions in Road Traffic (TERIS) project, moving closer to establishing standardised laboratory methods for generating, analysing and predicting tyre wear.

The project, led by the Fraunhofer Institute for Structural Durability and System Reliability LBF, together with Fraunhofer ICT, Fraunhofer IGD and Fraunhofer IWM, aims to provide the tyre industry, testing organisations and environmental agencies with reliable and practical laboratory procedures for assessing tyre abrasion emissions.

The first project milestone has been completed following a successful review by an advisory board comprising industry experts.

The consortium has developed reference methods for tyre abrasion, particle analysis, tribological modelling, artificial intelligence-based surface analysis, a laboratory test bench concept, accelerated ageing techniques and volatile organic compound (VOC) detection.

According to the consortium, combining different particle collection and measurement techniques enables more precise analysis of both airborne and deposited tyre wear particles. At the same time, tribological models have been developed to better understand the relationship between loading conditions, material properties, surface structures and particle formation, allowing real-world tyre wear processes to be replicated under laboratory conditions.

Researchers have also developed a specialised test chamber for accelerated ageing, enabling tyre samples to be exposed to controlled environmental conditions before evaluating their abrasion behaviour.

Another development is an optical detection system that uses artificial intelligence to identify and classify surface structures. The system has been validated using substitute materials and is expected to be applied to rubber samples during the next phase of the project.

The consortium has also designed a laboratory test bench that combines multiaxial loading, controlled generation of tyre wear particles, targeted particle collection and integrated optical sensors within a single testing platform.

In addition, the project combines accelerated weathering with chemical analysis of volatile organic compounds released from tyre abrasion to assess the environmental impact of tyre wear particles.

The researchers said the work will provide the foundation for faster and more practical laboratory evaluation of new rubber compounds. The resulting methods are intended to help tyre manufacturers reduce emissions, accelerate product development and support compliance with the requirements of the Euro 7 standard.

At Fraunhofer IWM, researchers focused on refining tribological wear models and friction surface concepts to simulate particle formation under controlled laboratory conditions. The institute designed a parameterisable wear test that studies friction between plate materials and model surfaces with different structures, enabling researchers to investigate the mechanisms responsible for particle generation.

Initial findings indicate that tyre wear results from multiple interacting mechanisms rather than a simple relationship between particle emissions and factors such as speed, contact force or temperature. The researchers collected and analysed particles across a wide range of sizes during the study.

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ZF has secured a significant milestone in the Indian automotive sector, receiving three major orders for its advanced test systems. The contracts, which encompass battery, tyre and e-axle testing, position the global driveline and chassis technology leader at the forefront of the nation’s drive to enhance road safety and establish more robust vehicle certification processes. This development aligns with India’s accelerating regulatory efforts to ensure that vehicle testing becomes more independent, rigorous and comprehensive, marking a critical step forward for the industry.

A key aspect of ZF's strategy involves a strong commitment to local manufacturing, with the company emphasising high levels of domestic content for its test systems in support of the ‘Make in India’ initiative. The firm’s extensive background in the field is underscored by its experience in testing over 100 million transmissions, a testament to the proven global reliability of its technology. This foundation of expertise is now being applied to address the specific safety and performance demands emerging in the Indian market.

With the rapid adoption of electric vehicles, battery safety has become a paramount concern, and ZF’s solutions cover the complete spectrum from individual cells to complete packs. These systems evaluate performance, endurance and environmental factors, including rigorous mechanical abuse testing, while adhering to a wide array of international and Indian standards. Furthermore, the company’s tyre testing capabilities are poised to play a crucial role as India prepares to enforce new mandatory regulations, including the BNVSAP and the AIS 142 TPMS Mandate. The ZF Tyre Efficiency Tester (TET.lab), recognised for its precision, offers a modular platform capable of testing everything from motorcycles to heavy commercial vehicles.

The company’s e-mobility test benches feature a high-performance drive module with a flexible, modular architecture designed to accommodate both conventional and electric drivetrains. These systems can be configured for various operations, integrating frequency converters and precision measurement technology for comprehensive testing. ZF’s deep expertise, already deployed by manufacturers and testing authorities worldwide, positions it as a key technology partner for India. As regulatory requirements tighten and the demand for quality escalates, the company is set to support the nation's ambition of building a safe and sustainable automotive ecosystem.

Akash Passey, President, ZF Group India, said, “Testing agencies are the final arbiters of vehicle safety, the bodies whose certification regulators and the public trust. Being chosen across three independent and Government agencies, for three distinct testing disciplines, is a powerful validation of ZF's accuracy, reliability and deep understanding of India's regulatory and testing landscape. ZF Group is proud to provide the technical foundation that makes world-class automotive safety infrastructure possible in India, not just for our OEM customers but also for Government and independent testing agencies.”

Thomas Trebitsch, Vice President, ZF Test Systems and Testing, said, “Over the past years, we have been focusing on the tyre industry in India and introducing our complete product portfolio to India. As the market develops rapidly towards regulations and safety, there is a strong need for robust and world-class testing technology. ZF brings its global competence and a deep understanding of the Indian auto industry to address its specific needs.”

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