Optical Comparators - Still Measuring Up On The Shop Floor

OPTICAL COMPARATORS—DOES THE QUALITY CONTROL INSTRUMENT STILL MEASURE UP ON THE SHOP FLOOR?

Part 3 of our Countdown to IMTS 2026 Series 

Digital vision systems and CMMs have captured much of the precision market, but optical comparators have served manufacturers for more than a century. Today, comparators remain a common fixture on U.S. shop floors performing two-dimensional, non-contact measurements for simple profile and radius inspections. For more than 35 years the AIMS Certified Comparator Products (CCP) team has led the industry in rebuilding and upgrading these workhorses. These skilled technicians routinely rebuild systems like OGP, J&L and Starrett into modern inspection tools with new electronic digital readouts and LED lighting. The service these models provide remains essential for manufacturers who are working with profiles that need to be magnified for inspection.

HOW DO COMPARATORS FIT INTO MANUFACTURERS’ INSPECTION NEEDS?

Over the last few years, the number of working machines larger than 30 inches has dwindled as the cost to build new comparators has risen. AIMS’ CCP team has sourced a large number of 20-inch and 30-inch chassis and rebuilt them to better-than-new condition. We built these systems around the best telecentric optics available and then rework the stages and upgrade the scales and digital readouts. We also offer a complete LED lighting kit for both profile and surface illumination. These systems also carry a one-year warranty.

IS SERVICE AVAILABLE FOR REBUILT OPTICAL COMPARATORS?

AIMS’ CCP division offers full-service options for thousands of current systems in the field. This support keeps inspections accurate and prevents production bottlenecks. Cleanliness of the optics and the full optical path is often overlooked yet the service is critical to help maintain a crisp, well-lit image. Most calibration houses do not have the time or expertise to properly service the system’s interior. This process must be performed carefully as the mirrors or highly reflective coating applied to the front of the glass are used to prevent ghosting yet can be scratched or easily damaged.

CAN SPARE PARTS STILL BE SOURCED FOR LEGACY OPTICAL COMPARATORS?

Over the last decade parts obsolescence for optical comparators has become increasingly challenging. Recently we became aware that there was a growing scarcity of the servo chassis that powers the drive for OGP floor models built before 2014. AIMS’ CCP team responded by designing, engineering and building a full replacement kit that uses a modern servo and motor. The drive kit provides an upgrade/repair path for legacy machines in the field and is standard on the OGP floor models AIMS provides. The new kit is a good example of how we are continually adding companies like CCP to expand our engineering capabilities. CCP is committed to continually adapting to the needs of the optical comparator community.

At IMTS 2026 AIMS will exhibit both a QL-20 and a QL-30. The equipment will feature the new drive system along with the latest in LED lighting and digital readouts. Visitors will be able to talk to our service personnel and see the kit firsthand to understand how it works and how it is installed. The QL-20 will have a transparent panel to allow individuals to see the inner workings of the install and what the finished product looks like. Make sure you take a few minutes to stop by and see us in Chicago September 14-19 Booth 134242.