3D Video Projection

Twin Coast Metrology’s 3D video projection products cut defects and reduce process time.


Build Assist is a real-time (video rate) 3D projection software capable of live updates of 3D information. The source of the 3D information can include real-time results from laser trackers, portable CMMs, photogrammetry systems, or other real-time acquisition devices. This live feedback directly onto the part allows personnel to view results in real-time as a part is built or inspected, thereby ensuring that a part is built correctly the first time.


The cameras and projectors in Twin Coast Metrology’s systems behave as a single network. Every optic in the system functions either independently, or as a group with other optics. This allows for intelligent selection of the “brightest” set of projectors for each illuminated area, and allows for highly-flexible deployment of hardware. In some cases, it is preferable to install optics surrounding an object, and sometimes it is preferable to track an object as it moves. Other times, it is useful to project on multiple objects simultaneously, or independently. TCM’s architecture handles all of these scenarios — in most cases automatically. By associating the optics within a network, a higher degree of accuracy, projector resolution, projector brightness, and operator confidence results.

Augmented Reality Projection Software



Twin Coast Metrology’s augmented-reality projection software, Assembly Assistant, projects work instructions directly into the manufacturing area. It is ideal for high-value, manual, assembly work. It reduces defects and cuts assembly time by allowing the manufacturing personnel to stay focused on the work area, rather than constantly switching focus to look at blueprints, or even worse, doing the assembly from memory.

Our customers realize a 50% decrease in assembly defects, and a decrease in assembly time when adopting our projection system.

3D Projection on A Panel
3D Projection on A Panel


The assembly assistant software supports

  • Up to 16 projectors, any manufacturer, any interface, any throw ratio, with no modifications.
  • Up to 16 cameras, 100’s of possible compatible cameras and lenses.
  • Up to four teams may use the system at once
  • Up to 4 ZigBee remotes
  • Up to 4 concurrent Fischer Technology Coating Thickness Gage’s.
  • Wireless gage integration with MobileCollect’s MicroRidge base station.
  • Fully 3D, the programmer has full control of where the light is projected on the part.
  • Any projector configuration is possible, portable head, 360 degrees around a part, straight down on a table, and horizontally onto a wall.
  • The job authoring software is included with the system.
  • Over 180 built point projection symbols.
  • Project 3D Lines, 3D filled Polygons, and Colored surfaces projection. Project coating masks, adhesive locations, and part assembly orientations.
  • Flexible Data Import, File Formats: STL, PLY, CSV, WRL, DXF, and GOM G3D. Tested with files generated by CATIA and Solidworks.
  • Built in part number database, to support installing fasteners, bolts, cleco, click studs, setup bolts, nuts, or nut plates.

Job Editor Screen Shot
Job Editor

COTS Hardware

The assembly assistant software supports building systems from COTS hardware.

Twin Coast Metrology COTS Hardware
Twin Coast Metrology COTS Hardware

Software Development Kit (SDK)

The assembly assistant software has an SDK to allow end users to perform system integration themselves.

Paint Masking Projection


With Twin Coast Metrology’s ProjectorGage paint, coating, or gel masking system, existing paint schemes can be projected directly onto a part in full scale and full color. This ability allows for the previewing of what the paint schemes will look like in full size prior to the finishing process. it also makes the masking process much faster when you have a high number of schemes.


  • Project on any shape part, 3D complex surfaces included.
  • Works for any kind of masking task, coating, paint, or gel.
  • Can project solid masks as well as lines in any color. Laser Projectors can only display a single blinking line.
  • Software is included, easy to use, and highly customizable
  • Durable and easy to maintain with commercial off the shelf components. Maintenance for laser projectors wear is expensive.
  • Multiple simultaneous projectors allow for the line to still be vivid when the operator is applying mask tape. Laser projectors unit cost is 20x higher than a video projector, less of them can be used in each application, limiting line of site options.
  • Import 3D polylines straight from CAD into projection software, no translation/conversion needed.

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Assembly Assistance Projection

Project work instructions directly on the part and cut manufacturing defects and cycle time by 50%.tcmproj2Installation of Complex Assemblies

Twin Coast Metrology’s ProjectorGage product can significantly reduce assembly time by projecting work instructions directly on the part, rather than requiring the operator to rely on a paper print or computer screen. Symbols, lines, filled areas, colored areas, animations, instructions, and part numbers are visible directly on the part surface in 3D!

CAD data and digital formats

ProjectorGage imports 3D data including polylines, surfaces.

Integration with Hand Tools

ProjectorGage guides an operator to specific locations, and measurements are collected with 3rd-party devices.


Visually Intuitive

With virtually no training, personnel can build complex assemblies.  This reduces mistakes, re-work, and allows for productive work from the get-go.



Whether assembling a bread box or a full-size airplane, ProjectorGage is scalable to make sure all surfaces are illuminated, and all work areas are covered.


ProjectorGage is fully supportable in the field.  The system can be maintained long-term using  COTS parts and calibration methods that can be performed by maintenance personnel.

Twin Coast Metrology COTS Hardware
Twin Coast Metrology COTS Hardware