Book a Call
AIM Systems · fixed-position, robot-guided & area measurement

Point & Area Coating Thickness Measurement Systems

Measure coating thickness at a selected position, along a robot-guided sequence, or across a defined camera area—on small parts, large assemblies, or a fixed lane of moving material.

Choose a measurement solution Request sample testing
Authorized AIM Systems U.S. sales & applications support partner. Gauge Advisor supports consultation, system selection, sample evaluation, integration, commissioning, and service.
AIM CoatPro system for non-contact coating thickness measurement at defined points
AIM CoatPro XD system and thickness heat map for defined-area coating inspection
Choose the coverage, then configure the motion. CoatPro returns a single value, a continuous trend at one qualified position, or a programmed series of point readings; CoatPro XD maps thickness over an area visible to the camera.
Point values
Programmed sequence
Area thickness map
Non-contactMeasure without touching or damaging the coated surface
Flexible deploymentLaboratory, fixed production station, or robot-assisted inspection
Automation readyRecipes, data export, and project-specific robot or programmable logic controller (PLC) integration
Application testedCoating, substrate, range, geometry, and cycle time evaluated together
Start with the inspection goal

What measurement coverage do you need?

A fixed-position value, a programmed sequence, and an area map answer different questions. Choose the output first; then qualify the coating, substrate, product geometry, range, motion, and cycle time.

Application-tested position · CoatPro

Measure the same critical position every time

Position CoatPro at a defined location relative to the coated surface and record thickness without touching it. The sensor can inspect a stationary sample, a part indexed into position, or one fixed lane as material moves beneath it.

  • Best whenA drawing identifies a critical location, quality needs a repeatable check, or production needs a continuous thickness trend at one selected lane.
  • What you getA calibrated thickness value at the application-tested position, plus trends and records configured for the inspection process.
  • Typical setupLaboratory or near-line fixture, fixed production sensor, or controlled product presentation.

Fit note: the coating and substrate, thickness range, surface condition, distance, angle, and accepted reference method must be qualified together.

Request point-measurement testing Explore CoatPro
AIM CoatPro non-contact coating thickness sensor and measurement software
CoatPro reports thickness at the application-tested position under the sensor.
Programmed motion · CoatPro

Inspect a repeatable sequence of locations

Move CoatPro with a robot or move the coated product through a controlled sequence. Each reading is associated with a known location, helping production inspect large, curved, or multi-feature surfaces without relying on manual spot checks.

  • Best whenSeveral locations matter, the product is large or curved, or inspection must follow the same route and order on every cycle.
  • What you getA list or location-based profile of point values collected along the programmed motion.
  • Typical setupCoatPro on a robot or linear axis, or a fixed sensor with automated product presentation.

Important: a robot increases point coverage by moving the sensor; it does not turn CoatPro into an instant area camera. Motion, sensor-to-surface distance (standoff), angle, cycle time, and collision clearance require review.

Review an automated sequence Compare deployment options
AIM CoatPro integrated into an automated coating inspection workflow
Programmed motion lets CoatPro inspect the locations that matter without contacting the coating.
Thickness distribution · CoatPro XD

See thin and heavy areas in one thickness image

CoatPro XD uses thermographic camera modules to show coating-thickness distribution over an application-tested field of view—the area visible to the camera. Regions of interest can focus evaluation on edges, features, or areas where uniformity matters.

  • Best whenA few points could miss local variation, coating uniformity matters, or engineering needs a visual thickness map.
  • What you getA calibrated thickness image with project-defined regions of interest, evaluation rules, and export options.
  • Typical setupOne camera module for a defined area or multiple modules and views for greater coverage or resolution.

Fit note: field of view, required spatial detail, curvature, line of sight, working distance, camera count, and cycle time determine how much of the coated surface is covered.

Request area-mapping testing Explore CoatPro XD
CoatPro XD coating thickness map showing variation near a coated edge
Area maps can reveal local thin and heavy regions that a small set of point readings may miss.
Feasibility before configuration

Prove the coating and measurement before buying hardware

Photothermal measurement is application-specific. Representative coated products and reference samples help determine whether the coating can be measured, which platform fits, what precision and cycle time are realistic, and how calibration should be built.

  • Best whenThe material combination is new, the coating is reflective or transparent, the range is very thin or very thick, or the surface geometry is difficult.
  • What you getA feasibility result based on representative materials, reference values, and the intended inspection goal.
  • Typical setupStart in the application laboratory, then translate the qualified measurement into a lab, near-line, or production system.

Calibration note: reference accuracy sets a limit on measurement confidence. Avoid extrapolating beyond the qualified thickness range.

See what to send Read the technology guide
AIM Systems application testing and coating measurement validation setup
Representative samples reduce risk before the sensor, optics, calibration, motion, and controls are finalized.
Photothermal measurement in plain language

How AIM measures a coating without touching it

The sensor reads how the coating responds to controlled light. A material-specific calibration converts that response into thickness.

Excite the coating

A modulated LED illuminates the measurement area and creates a small repeating thermal response.

Read the response

An infrared detector measures how the thermal signal returns from the coating surface.

Separate useful signal

Lock-in processing listens for the response at the known modulation frequency and reduces unrelated background effects.

Convert signal to thickness

A calibration built from qualified reference samples translates the measured response into a coating-thickness value or map.

Want the deeper physics?

The technology guide explains phase shift, thermal properties, calibration, multilayer considerations, and why sample testing matters.

Read the photothermal guide
AIM Systems platforms

Choose the platform by the output you need

CoatPro and CoatPro XD use related photothermal principles, but they collect different types of data. Neither is automatically the better choice.

AIM Systems — point, sequence & area coating measurement

German-engineered systems for fixed-position measurement, automated sequences, continuous measurement at a selected location, and thermographic area mapping, supported by application testing and project-specific integration.

Visit the AIM Systems website
AIM CoatPro sensor positioned over a coated surface for point measurement
Fixed positionContinuousProgrammed sequence

CoatPro

Use one sensor at a fixed location while material passes beneath it, move a product through a controlled sequence, or move the sensor with a robot. The output can be a single value, a continuous trend at one qualified lane, or a location-associated series from a programmed sequence.

Best for
Critical positions, fixed-lane trends, automated sequences, and repeatable production decisions
Published range
Typically 1–1,000 µm; configuration and application dependent
Integration
Power over Ethernet (PoE), Modbus TCP, synchronized sensors, PNG and CSV export
Review a CoatPro application View current manufacturer details
AIM CoatPro XD modular thermographic coating thickness mapping system
Area mapRegions of interestModular cameras

CoatPro XD

Use one or more camera modules to create a thickness image over an application-tested field of view. Regions of interest can highlight local thin or heavy areas, edges, and coating distribution.

Best for
Local uniformity, defined-area inspection, edge effects, and visual thickness distribution
Published range
10–1,000 µm; configuration and application dependent
Integration
Modbus TCP, modular camera groups, measurement campaigns, PNG and CSV export
Review a CoatPro XD application View current manufacturer details

CoatPro — representative published specifications

Use these values for preliminary comparison, not as guaranteed application performance.

Thickness range
Typically 1–1,000 µm
Working distance
Typically 100 mm with ±50 mm tolerance
Angle tolerance
Typically ±75°
Modes
Single point, continuous, and robot sequences

CoatPro XD — representative published specifications

Field of view, detail, coverage, and measurement time are configured around the target area and application.

Thickness range
10–1,000 µm
Typical field
30 × 20 cm with typical lateral resolution below 1 mm
Working distance
25 cm to over 100 cm; typically 50 cm
Architecture
One or more synchronized or independent camera groups
AIM coating measurement software displaying thickness results and controls
Software & production integration

Turn the sensor reading into a usable inspection record

The measurement head is only one part of the system. Calibration, recipes, product or part identification, evaluation rules, motion, and data handling determine whether the result works in production.

  • CoatPro supports point, continuous, sequence, and synchronized multi-sensor workflows.
  • CoatPro XD supports camera grouping, measurement campaigns, regions of interest, and combined thickness images.
  • Both platforms provide guided calibration and graphical or text-based exports; robot, PLC, pass/fail, and database interfaces are defined for the project.
Discuss automation & data needs

Specification note: published ranges and geometry values describe representative manufacturer configurations. Coating chemistry, substrate, optical absorption, thermal contrast, surface condition, calibration, range, angle, working distance, measurement time, and desired precision determine actual performance. Hazardous-area use requires the appropriate ATEX version for explosive-atmosphere installations and an application-specific safety review; ATEX does not automatically establish North American classified-area approval.

From R&D to automated production

Point and area measurement can work in the lab or in production

The same qualified measurement can move from application testing to a lab fixture, a fixed position over moving material, a near-line station, or a fully automated cell. The best deployment depends on coverage, cycle time, product presentation, and decision logic.

01

Laboratory and R&D

Develop the calibration, compare coating trials, establish the qualified range, and decide whether point values or an area map answer the engineering question.

02

Near-line fixture

Inspect samples or parts next to production at repeatable locations for quality checks, setup verification, incoming inspection, or structured batch sampling.

03

Fixed production position

Measure one selected lane continuously as material moves beneath the sensor, or measure a critical location as each part indexes into position.

04

Robot or multi-camera cell

Use controlled motion for a CoatPro point sequence or configure CoatPro XD camera groups and views for greater area coverage.

Preliminary comparison

Compare point, sequence, and area measurement

The platform follows the inspection question. A final recommendation still requires representative samples and a review of the complete measurement setup.

AIM point, sequence, and area coating measurement comparison
Inspection needPlatformCoverageRequired motionPrimary outputBest fitMain qualification question
Fixed positionCoatProOne qualified location or laneNone after positioning; product may move beneath the sensorThickness value and continuous trendCritical feature, one web lane, process-control position, or repeatable quality checkCan the coated surface remain within the qualified distance and angle?
Programmed sequenceCoatProOrdered set of qualified pointsRobot, axis, or controlled product motionLocation-based point profileLarge, curved, or multi-feature parts and assembliesCan motion, sensor-to-surface distance, cycle time, and collision clearance be controlled?
Defined area mapCoatPro XDQualified camera field of viewNone for one view; added motion or cameras for more coverageThickness distribution and regions of interestUniformity, edges, local thin or heavy areasWhat field of view, spatial detail, line of sight, and cycle time are required?
Multiple simultaneous pointsMultiple CoatPro sensorsSeveral qualified locationsFixed or synchronized presentationSynchronized point valuesFast production checks at several known locationsAre the locations accessible and is each coating response qualified?

Point, sequence, and area are not quality grades. Choose the least complex workflow that captures the variation you must control. An area map is useful only when local distribution matters; a repeatable point may be the faster and clearer production measurement.

Application examples

Start with the coating and required coverage—not product size

AIM can measure small parts, large assemblies, stationary samples, or a selected lane of moving material. These application pages cover the process-specific questions in more detail; representative samples determine the final solution.

E-coat and electrophoretic deposition

CoatPro supports repeatable measurements at qualified locations before or after bake. A whole vehicle or large assembly is a programmed point sequence—not one instant area scan.

Explore e-coat measurement

Powder-coated parts

Evaluate defined points, robot-assisted sequences, or qualified area maps on wheels, housings, trays, brackets, and other metal components.

Explore powder coating measurement

Rare-earth magnets

Inspect protective nickel, epoxy, zinc, and other qualified coating systems on small or geometrically challenging magnetic components.

Explore magnet coating measurement

Thin-film and functional coatings

Review optical and thermal fit for primers, protective layers, adhesives, dry lubricants, plated finishes, and technical coatings on discrete parts.

Explore functional coating measurement

EV battery and cooling components

Measure qualified insulation and powder-coating systems on cell housings, cooling ribbons, trays, and related components. After application feasibility testing, CoatPro may follow one fixed lane on moving material; use Scantech when the requirement is full-width electrode basis weight or profile.

Explore EV component coating measurement

Do you need a full profile across a continuous web?

A fixed CoatPro can follow one application-tested lane as film, foil, paper, or another coated product moves beneath it. If you need a scanner to traverse the complete web width—or need coating basis weight, density, tension, or guiding—review the Scantech and FMS web solution.

Explore full-width web coating measurement
Reduce application risk

What we need for a useful sample evaluation

Send the coating, product, and measurement goal—not an equipment guess. The information below helps AIM determine measurability, realistic precision, required measurement time, and the most practical platform.

Application information

Provide as much of this as possible. A drawing, line sketch, or annotated photo is often more useful than a long email.

  • Coating and substrate materials
  • Single layer or multilayer stack
  • Wet, uncured, baked, or fully cured state
  • Expected range and tolerance
  • Accepted reference method and samples
  • Product size or web width, curvature, and recesses
  • Fixed position or lane, programmed sequence, or mapped area
  • Line speed, cycle time, and sampling plan
  • Fixture, line, robot, PLC, and data interfaces
  • Environment and hazardous-area needs
  • Traceability, reports, and pass/fail needs
  • Representative production variation

How sample testing helps

Photothermal performance depends on the full coating/substrate system. Representative references let the application team test the measurement before the production architecture is finalized.

  1. Confirm that the coating response is measurable.
  2. Build or review a calibration with known reference thicknesses.
  3. Estimate achievable repeatability and measurement time.
  4. Review distance, angle, curvature, motion, and field of view.
  5. Recommend CoatPro, CoatPro XD, or additional feasibility work.
Request a sample evaluation
Useful next steps

Guides and engineering tools

Use the technical guide for deeper measurement physics; use the tools for preliminary economics and quality planning.

Technology guide

Photothermal Coating Thickness Measurement

Understand the measurement principle, calibration, material fit, and common limitations.

Read the technology guide ROI

Coating Measurement ROI Calculator

Estimate the value of reduced scrap, rework, delayed feedback, and manual inspection effort.

Estimate measurement ROI Quality tool

Cpk & Ppk Process Capability Calculator

Relate measured process variation to specification limits after a stable measurement is established.

Calculate process capability Solution hub

All Coating Measurement Solutions

Compare AIM point and area measurement with Scantech full-width web profiles and FMS web handling.

Return to coating solutions
Frequently asked questions

AIM point and area coating measurement FAQs

Plain-language answers to the questions that most often change the system recommendation.

What is the difference between CoatPro and CoatPro XD?
CoatPro measures thickness at a selected position. It can remain fixed while coated material moves beneath it, measure parts as they index into place, or follow a programmed sequence with a robot or axis. CoatPro XD uses thermographic camera modules to create a thickness-distribution map over a qualified field of view. Choose based on the output you need, not on which platform appears more advanced.
Does a robot make CoatPro an area scanner?
No. A robot moves the point sensor through known locations, producing an ordered set of point measurements. That can provide broad coverage, but it is not the same as an instantaneous area image. CoatPro XD is the area-mapping platform.
Can CoatPro XD measure an entire part in one image?
Only when the required area fits within the qualified field of view and has suitable line of sight. Larger or complex products may need more camera modules, multiple views, controlled motion, or a different inspection strategy. Curvature, recesses, desired spatial detail, and cycle time all affect coverage.
Can CoatPro measure coating thickness on a moving web?
Yes, in an application-qualified installation, a fixed CoatPro can measure continuously at one selected lane as coated material moves beneath it. That produces a thickness trend at that location; it does not create the full side-to-side profile of a traversing Scantech scanner. Use the required coverage—not whether the product is called a web or a component—to choose the architecture.
Can AIM measure wet or uncured coatings?
AIM lists both platforms as suitable for wet or uncured coatings, but the specific coating and substrate still require evaluation. A wet measurement should not automatically be described as final dry-film thickness; predicting the dry result requires a validated wet-to-dry correlation.
Can photothermal measurement work on every coating?
No measurement method is universal. Suitability depends on optical absorption, thermal-property contrast between coating and substrate, thickness range, surface condition, geometry, working distance, angle, measurement time, and calibration. Reflective, transparent, light-colored, metallic, or multilayer systems deserve specific sample testing.
How is the system calibrated?
Calibration uses representative samples with known reference thicknesses for the qualified coating/substrate combination and range. Reference-sample accuracy directly affects measurement confidence. More than one reference point is normally needed, and extrapolation beyond the calibrated range should be avoided.
Does non-contact measurement mean no safety review is needed?
No. AIM’s LED-based photothermal technology is eye-safe and uses no ionizing radiation, but the complete installation still requires machine, automation, electrical, and environmental review. Hazardous-area use requires the appropriate ATEX version and application-specific review; ATEX does not automatically establish approval for a North American classified area.
Can the measurement be integrated into production?
Yes, when the application is qualified and the machine interface is defined. CoatPro supports Ethernet/PoE and Modbus TCP; CoatPro XD supports Modbus TCP and may support other project-specific protocols. Product motion, robot motion, PLC handshakes, recipes, pass/fail rules, tracking, data storage, and safeguards must be engineered for the production installation.
What should I send for an application review?
Send the coating and substrate, layer structure, wet or cured state, expected range and tolerance, accepted reference method, product drawing or line sketch, desired position, sequence, or mapped area, line speed or production cycle time, automation plan, environment, and representative samples across normal process variation.
Application-first support

Send the coating, product, and measurement goal

We will help determine whether the practical solution is a fixed-position CoatPro measurement, a programmed CoatPro sequence, a CoatPro XD area map, or additional feasibility testing before equipment is specified.

Request an application review Schedule a call

Gauge Advisor is AIM Systems’ authorized U.S. sales & applications support partner. Final recommendations may require representative samples, reference measurements, application testing, product and machine review, integration planning, and project-specific safety evaluation.