In the world of precision manufacturing, Coordinate Measuring Machines (CMMs) are critical tools used to inspect the dimensions and geometry of components. However, as technology evolves, older CMMs may become outdated due to obsolete software and hardware. Instead of replacing the entire machine—an expensive and often unnecessary investment—many manufacturers are turning to CMM retrofit software to modernize their equipment.
In this article, we’ll explore what CMM retrofit software is, its benefits, how it works, key features to look for, and the best software options available today.
What is CMM Retrofit Software?
CMM retrofit software refers to updated, modern software installed on older or legacy CMM hardware to improve functionality, accuracy, and compatibility with current technologies. Retrofit software allows manufacturers to extend the lifespan of their existing machines while enabling them to perform new types of measurements, generate digital reports, and connect with other systems like CAD software or Quality Management Systems (QMS).
Retrofit software is typically paired with new controllers, probes, or interface systems to bridge the gap between old hardware and modern inspection needs.
Why Retrofit Your CMM?
1. Cost-Effective Modernization
Upgrading an entire CMM system can cost hundreds of thousands of dollars. Retrofitting with updated software and minimal hardware changes can bring similar capabilities at a fraction of the price.
2. Enhanced Accuracy and Performance
Retrofit software improves data processing speed, enables more advanced algorithms, and often supports new probing technologies—resulting in higher accuracy and better repeatability.
3. Extended Equipment Lifespan
Many CMMs have strong, durable frames and mechanical systems that remain functional for decades. Retrofitting allows you to continue using this solid infrastructure while updating only the digital interface.
4. CAD Compatibility
Modern software enables direct CAD model import, letting operators compare measurements with design specifications easily.
5. Improved Reporting and Analysis
Generate automatic inspection reports, statistical process control (SPC) data, and real-time graphical feedback with modern reporting tools included in retrofit software.
How Does CMM Retrofit Software Work?
Retrofit software works by integrating with the existing CMM hardware and replacing or interfacing with its control system. Here’s a general breakdown of how a retrofit process is carried out:
- Assessment of Existing Hardware: Evaluate the CMM structure, controller, and probing system.
- Software Installation: New software is installed on a modern PC or controller system.
- Hardware Interface: If needed, new controllers or retrofit kits (e.g., Renishaw UCC or Pantec Eagle) are added.
- Probe Integration: The system is calibrated to work with existing or new touch probes or scanning probes.
- System Testing and Calibration: The updated system is tested for accuracy and performance validation.
Key Features to Look for in CMM Retrofit Software
When selecting retrofit software, here are some essential features and capabilities to consider:
1. CAD Model Support
Ensure the software supports 2D and 3D CAD file imports (e.g., IGES, STEP, Parasolid, SolidWorks).
2. User-Friendly Interface
Modern GUIs should be intuitive, allowing operators to set up measurements and inspections without extensive programming.
3. Multi-Probe Support
Compatibility with various probe types—touch-trigger, scanning, and vision systems—offers greater flexibility.
4. Real-Time Reporting
Instant data visualization and automatic report generation help speed up quality control processes.
5. Offline Programming
Program measurement routines away from the machine to increase uptime.
6. Compatibility with Existing Hardware
Look for software that integrates with your current controller and probe system to reduce hardware costs.
Best CMM Retrofit Software Solutions
Several retrofit solutions are available today, each offering unique features. Below are some of the most trusted options:
1. PC-DMIS
Developed by Hexagon Manufacturing Intelligence, PC-DMIS is one of the most widely used CMM software platforms. It supports both touch and scanning probes and offers strong CAD integration. It’s ideal for complex geometries and aerospace or automotive parts.
2. MODUS
Renishaw’s MODUS software works seamlessly with their UCC controller systems. It offers powerful reporting, advanced scanning features, and full compatibility with REVO and PH20 probing systems.
3. CMM-Manager
Created by QxSoft, CMM-Manager is designed specifically for retrofits. It features a highly visual interface, supports CAD programming, and is compatible with a wide range of CMM brands.
4. Metrolog X4
Metrologic Group’s Metrolog X4 supports legacy CMMs and delivers high-speed processing, multi-sensor support, and excellent GD&T analysis. It also integrates with many controllers and robot-based systems.
5. PolyWorks Inspector
Ideal for high-end 3D scanning and probing, PolyWorks is used for both CMMs and portable metrology equipment. It’s known for real-time inspection capabilities and robust statistical analysis tools.
Benefits of Retrofitting vs. Buying New
| Aspect | Retrofitting | Buying New |
|---|---|---|
| Cost | Low to Moderate | High |
| Setup Time | Short (days) | Long (weeks/months) |
| Learning Curve | Low (familiar machine) | Moderate to High |
| Hardware Usage | Reuse existing components | New machine entirely |
| Customization | Highly customizable | Factory pre-set |
For many small to medium manufacturers, retrofitting represents the best balance between cost and performance.
Industries That Benefit from CMM Retrofit Software
- Automotive Manufacturing
- Inspection of engine blocks, pistons, and gears.
- Aerospace
- Tight tolerance parts like turbine blades or fuselage components.
- Medical Device Manufacturing
- Precision measurement of implants and surgical tools.
- Defense and Military
- Dimensional validation of defense-grade hardware.
- General Engineering
- Multi-part inspection processes for industrial components.
Challenges of CMM Retrofitting
While the benefits are numerous, there are some potential drawbacks to consider:
- Compatibility Issues: Not all software works with all controllers or probe systems.
- Installation Complexity: May require professional calibration and setup.
- Licensing Costs: Some advanced software options come with high licensing fees.
- Training Requirements: Operators may need to be retrained on new interfaces and tools.
However, with proper planning and support from the retrofit provider, these challenges can be managed effectively.
Conclusion
CMM retrofit software offers a smart, efficient way to modernize aging coordinate measuring machines without breaking the bank. With advanced measurement capabilities, CAD compatibility, and enhanced user experience, retrofitting can bring legacy equipment into the digital manufacturing age.
Whether you’re a small manufacturer or a large-scale enterprise, investing in CMM retrofit solutions can significantly improve quality assurance, reduce costs, and increase productivity. As inspection demands continue to grow, keeping your CMM systems up-to-date through retrofitting is a strategic move toward smarter manufacturing.