Renishaw Introduces First On-Machine Ultrasonic Thickness Measurement Probe for Machine Tools

Global engineering technologies manufacturer Renishaw is launching the RUP60, an advanced ultrasonic thickness measurement probe designed for the metalworking and heavy manufacturing industries. This hardware enables automated, single-sided thickness verification directly on machine tools, eliminating the need to transfer large components to specialized inspection stations.

Eliminating Manual Measurement in Metal Machining
Traditional methods for measuring large metal workpieces require significant factory floor space and are highly susceptible to operator errors, such as inadequate coupling or incorrect positioning. The technology addresses these limitations by providing an automated on-machine measurement solution for materials ranging from 0.7 millimeters to 30 millimeters in thickness using a single stylus. The hardware will be demonstrated at IMTS 2026 in Chicago from September 14 to 19, 2026, and at AMB 2026 in Stuttgart from September 15 to 19, 2026. By keeping the workpiece on the machine, the system streamlines digital supply chain logistics and reduces overall production steps.

Ultrasonic Data Processing and Radio Transmission Mechanisms
The system ensures precise measurements essential for adaptive machining cycles, commonly referred to as cut-measure-cut operations. The probe captures thickness measurements in two seconds per point, achieving an accuracy better than 10 micrometers and a repeatability of 2 micrometers. It functions reliably in harsh manufacturing environments, with or without the use of coupling fluid. Communication with the machine tool controller is managed via the RMM-QE radio receiver, utilizing the established QE radio transmission protocol. Furthermore, a Universal Sensor Interface processes the high-volume data generated by the non-destructive ultrasonic method. Heather Ormston, Lead Product Marketing Engineer for Renishaw's Machine Tool Products Division, notes that adapting ultrasonic thickness measurement to the machining environment facilitates in-process measurement and continuous data monitoring.

Integration with Existing Manufacturing Software Ecosystems
To support consistent inspection cycles, the probe integrates with established macro programming frameworks such as Inspection Plus. It also supports automated cycle generation through Set and Inspect software, enabling operators to program point measurements and calibration routines. Calibration can be executed on a separate artifact of identical material or directly on the primary workpiece if the thickness at a specific point is known. Compatibility with broader data management platforms, including Renishaw Central, allows the hardware to feed measurement data into a wider automated manufacturing data ecosystem for continuous process traceability.

Additional Context:
This section details technical specifications and competitive benchmarking not included in the original product announcement

Within the industrial metrology sector, ultrasonic thickness measurement is frequently handled by handheld devices or dedicated offline coordinate measuring machines produced by competitors such as Evident and Hexagon. The integration of ultrasonic capabilities directly into the machine tool spindle represents a shift toward in-line process control. Comparable on-machine metrology systems typically rely on tactile touch-trigger probes, which can only measure external dimensions and require physical access to both sides of a part to calculate thickness. By utilizing ultrasonic waves to measure material density and thickness from a single side, the new system offers a distinct mechanism for inspecting hollow, complex, or large-scale components where dual-sided access is geometrically impossible.

Edited by Natania Lyngdoh, Induportals editor, assisted by AI.

www.renishaw.com