EMO 2025: Bruker Alicona presents SensorX in Nagel's NaPrep cell

The SensorX is the first Bruker Alicona sensor specifically designed for seamless integration into third-party systems. Developed in close collaboration with a key customer and already in use in industrial production, the SensorX is now being launched as a fully mature and proven solution for inline and in-process metrology. The technology is based on Bruker Alicona's Advanced Focus variation and includes key innovations such as focus probing, vertical focus probing and a robust coaxial illumination system. This combination enables precise 3D measurements of shape and surface even in the most demanding production environments - including sharp edges and complex geometries - without contact or sample preparation. "SensorX is a breakthrough in metrology integration. It allows manufacturers to equip their machines with world-class optical metrology and gives them full traceability and automation potential - right at the point of production," explains Urban Muraus, Managing Director at Bruker Alicona.

NaPrep: Robot-based cutting edge preparation with inline measurement technology

NaPrep is an automated brushing cell developed by Nagel Technologies GmbH for the selective and defined rounding of cutting edges. Defined edge preparation extends tool life, improves chip flow and surface quality and reduces the risk of chipping. At the heart of NaPrep is a robot-assisted system that can machine shank tools (drills, milling cutters, taps) and inserts - even with complex free-form geometries. Optical sensors detect the tool orientation, while intuitive setup routines enable new tool types to be taught in quickly. NaPrep supports robot-supported process control, automatic wear compensation and a closed control loop with integrated measurement technology. Until now, the RS25 sensor from Bruker Alicona, which is based on Focus-Variation, has been used for this purpose. At EMO 2025 (September 22-26, 2025), the newly developed SensorX will be integrated into the system for the first time - with even greater measuring precision. This marks a significant further development of the cell architecture and enables fully autonomous edge preparation with traceable, reproducible results in unmanned production environments.

In focus at EMO: Nagel's NaPrep automation cell

To demonstrate real-life integration, the SensorX will be fully integrated into Nagel's NaPrep automation cell. This robotic system enables selective and automated cutting edge rounding with closed-loop quality control. The integrated SensorX ensures reliable edge detection, real-time process correction and automatic wear compensation - all in a single intelligent cell. With this cooperation, Nagel and Bruker Alicona are combining two complementary areas of expertise: robot-based micromachining and automated measurement technology. In addition to the premiere of the SensorX, Bruker Alicona will be showcasing a range of other systems representing the state of the art in optical 3D metrology for industry at its stand D20 in Hall 5 at EMO. Each system is tailored to specific applications in the fields of toolmaking, machining, medical technology and precision manufacturing.