Speed and precision are very important in today’s fast-paced manufacturing. However, there is a tradeoff between these two, as manufacturers often have to compromise one for the other. Hexagon’s newly introduced Leica Absolute Tracker ATS800 laser tracker is engineered to overcome this tradeoff. This advanced system provides high precision, accuracy, and in-situ inspection of large components directly where they are assembled or machined.

This article explores the key technical strengths of ATS800, such as its precision laser scanning capabilities, ease of use, and integration-ready design. It highlights the competitive advantages it offers in terms of efficiency, flexibility, and cost-effectiveness. Moreover, it examines the impact of ATS800 across high-stakes sectors, including aerospace, automotive manufacturing, and the heavy machinery industry. 

Why In-Situ Inspection Matters Today

In manufacturing environments of industries such as aerospace, automotive, and heavy machinery, components have increased in both scale and complexity. These components feature intricate geometries, tight tolerances, and critical surface features that require high-precision inspection at every production stage. Traditionally, verifying such components required moving them from the production line to dedicated measurement cells. 

Transporting large components from the production floor to dedicated measurement cells or metrology labs is costly and time-consuming. This movement can cause significant production downtime, which can be very expensive in industries like automotive and aerospace, where downtime costs can reach millions per hour. Handling large parts also risks damage or misalignment, which further increases costs and quality risks. Avoiding part relocation is thus a major driver for in-situ inspection.

Manufacturers require inspection solutions that provide immediate, high-accuracy data directly on the shop floor. 

Real-time inspection enables rapid detection of deviations and defects, which is necessary for immediate corrective actions without halting production. It eliminates relocation requirements, allows immediate feedback and correction, and enhances throughput by aligning measurement with manufacturing processes. 

Hexagon’s ATS800 laser tracker is engineered specifically to meet this need. It enables accurate, non-contact inspection directly at the point of production and helps manufacturers minimize downtime, maintain dimensional integrity, and assure quality. 

Introducing the Leica Absolute Tracker ATS800 

The Leica Absolute Tracker ATS800 is a state-of-the-art portable laser tracking system designed specifically for high-accuracy, large-scale industrial inspection and measurement tasks. 

The ATS800 integrates direct laser scanning and reflector tracking into a single compact device, enabling it to perform precise measurements of complex parts and assemblies. This hybrid capability allows users to capture detailed data on features such as edges, holes, slots, and threads without physical contact or close-range sensors. The system supports both automated and manual inspection workflows, which reduces setup time and operator workload.

The ATS800 is built to withstand the rigors of industrial environments. It features a rugged, IP54-rated construction that protects it against dust and water splashes for reliable operation on the shop floor. The entire system is compact and fits into a single transport case, allowing teams to move it easily between workstations or job sites. 

The system is battery-powered with hot-swappable batteries, allowing for cable-free, uninterrupted operation for over six hours. Moreover, its wireless connectivity through built-in Wi-Fi supports smooth integration with metrology software and Industry 4.0 platforms and enables remote operation and integration with digital workflows. 

The ATS800 can inspect parts at distances up to 40 meters with high accuracy. It achieves a measurement precision of ±21 micrometers plus an additional 8.5 micrometers per meter of distance, making it suitable for large-scale, high-precision components. 

Key Technologies that Power the ATS800

Hexagon has equipped the ATS800 with a suite of advanced technologies that collectively enhance speed, accuracy, and ease of use.

TruePoint Technology

TruePoint Technology of ATS800 utilizes advanced optics and real-time compensation algorithms to deliver highly accurate point data over extended distances. It corrects for environmental influences and ensures that measurements are true to the part’s actual geometry. This level of accuracy is important for minimizing costly rework and maintaining tight tolerances on large-scale components.

AI-Powered Feature Detection

The ATS800 incorporates sophisticated AI-driven algorithms that automatically recognize and classify geometric features like edges, holes, and surface transitions directly from scan data. This automation eliminates the reliance on manual feature selection, speeding up the inspection process and reducing the potential for human error. As a result, users can achieve faster throughput and more repeatable inspection results, especially in high-mix production environments.

PowerLock Tracking

PowerLock tracking is a technology that enables the ATS800 to instantly acquire and maintain lock on optical reflectors, regardless of their position or movement within the tracker’s field of view. This rapid re-acquisition capability is invaluable during dynamic measurement tasks, such as when parts or fixtures are repositioned. PowerLock ensures an uninterrupted scanning process. It also supports smooth transitions between multiple reflectors, which is particularly beneficial when inspecting large assemblies with several reference points.

Selective Scanning

Selective scanning helps users to define specific regions of interest on a component. The system intelligently distributes scan points within these user-selected areas, guaranteeing uniform point density and comprehensive coverage. This targeted approach optimizes scanning efficiency and also enhances data quality for critical features without overwhelming users with unnecessary information. Selective scanning is very useful for inspecting localized defects or high-tolerance zones and allows tailored inspection strategies that align with production priorities.

The ATS800 Advantage Compared to Traditional Systems

Measurement Versatility

Classic stationary CMMs are limited by their physical loading space and require parts to be brought to them, while portable measuring arms can be taken to the shop floor but can only inspect parts within their range of motion. The ATS800, on the other hand, combines range with fine-detail capability in a single, portable device. Its ability to scan objects up to 40 meters away while still capturing intricate features eliminates the need to choose between wide coverage and high precision.

Streamlined Workflows and Reduced Human Error

Traditional measurement methods usually involve labor-intensive setup, precise manual alignment, and frequent repositioning. Each such step introduces possibilities for error and consumes valuable production time. The ATS800’s advanced tracking and alignment technologies reduce the need for manual intervention. Operators can complete complex inspections with minimal input, allowing skilled staff to focus on higher-value tasks rather than repetitive setup and adjustment.

Operational Speed and Efficiency

Speed is another significant differentiator between traditional systems and ATS800. Manual measurement tools and even some scanning systems require lengthy calibration and alignment. The ATS800, on the other hand, is engineered for rapid deployment. Its intelligent alignment features allow inspections almost immediately after setup, reducing non-productive time and accelerating throughput on the shop floor.

Safety and Accessibility in Challenging Environments

The ATS800’s remote operation capability is a major safety and accessibility advantage. The ATS800 can be operated from a safe distance, keeping operators away from heavy machinery, moving parts, or hazardous materials. 

Cross-Industry Applications

In the aerospace industry, inspecting vast contoured surfaces such as fuselage assemblies and wing structures, often made from complex composites or aluminum alloys, is quite challenging. The ATS800 enables in-situ measurement of these components without the need to move them, maintaining structural integrity.

In the automotive sector, precision is extremely important in Body-in-White (BIW) inspection, where even minor misalignments can affect downstream processes. The ATS800’s ability to capture high-resolution data over large distances allows it to validate body panel fit, perform real-time flush and gap assessments, and verify fixture alignment directly on the production line without interrupting throughput.

In sectors such as heavy equipment manufacturing and power generation, the ATS800 is ideal for inspecting huge-sized and irregularly shaped structures. For example, it can quickly map the surfaces of massive turbine casings or construction equipment frames, detecting deviations that could affect performance or assembly.

Similarly, the ATS800 has relevance in industries like rail, defense, marine, and agriculture. For instance, ATS800 can be used to ensure the fit of armored vehicle panels or assess the structural frames of agricultural machinery. It provides the flexibility and performance needed to meet industry-specific demands with ease.

Automation-Ready: Scalable Solutions for Smart Factories

The ATS800 is designed as an automation-ready, scalable solution specifically tailored for smart factories with advanced manufacturing environments.

Compatibility with Autonomous Mobile Robots (AMRs)

The ATS800 can be mounted on AMRs for fully autonomous inspection workflows. Its wireless, battery-powered design and compact form factor facilitate easy integration with AMRs, overcoming traditional automation barriers such as bulky cabling and control systems.

Flexible Mounting Options

The system supports mounting on various mechanical setups, including rails, turntables, and robotic arms. This flexibility allows manufacturers to configure scanning setups that best fit their production lines and inspection needs. For example, it can be installed on a fixed rail system for linear scanning or on a robotic arm for dynamic, multi-axis scanning, enhancing adaptability to different part geometries and factory layouts.

Moreover, the ATS800 supports fixed installations involving multiple trackers operating simultaneously. This enables multi-angle scanning of large-scale assemblies. 

Integration with Hexagon’s Nexus Digital Platform

The ATS800 fits into Hexagon’s Nexus platform, which is a cloud-based connectivity and collaboration environment that powers smarter manufacturing through digitalization and AI. Nexus enables efficient data sharing, workflow automation, and integration with other digital tools and IoT devices across the production line. This connectivity supports real-time measurement, process alignment, and data-driven decision-making, helping manufacturers optimize quality and efficiency in a connected factory ecosystem.

A Future-Ready Solution Backed by Hexagon’s Legacy

The ATS800 is built on Hexagon’s decades of metrology leadership. It reflects a continuous commitment to innovation, reliability, and customer trust. Its certification to ISO 10360-10 and ASTM E3125-17 standards confirms that the system has undergone rigorous testing to guarantee accuracy and reliability. Hexagon’s global service and care packages provide comprehensive support, helping manufacturers reduce downtime, cut costs, and enhance product quality.

The ATS800 is engineered to address the challenges of modern-day manufacturing. 

This future-ready approach positions the ATS800 as more than just a measurement tool but a strategic asset for manufacturers seeking to stay competitive in a speed, precision, and adaptability-demanding market.

Conclusion: The New Standard for Large-Scale Laser Scanning

The ATS800 has set a new industry benchmark for large-scale, non-contact measurement by integrating precision, enhanced portability, and streamlined productivity into one system. This high performance, once reserved for specialized metrology labs, is now directly accessible in large-scale production environments.

Rather than adapting old inspection models to meet modern challenges, the ATS800 allows manufacturers to rethink their approach altogether.

If your current inspection process still relies on manual intervention, physical part movement, or outdated scanning systems, explore how the ATS800 can serve as a catalyst for a smarter, more resilient workflow—and begin future-proofing your production line today.

Would you like to learn more about Hexagon's laser trackers & scanners? Ask for a free DEMO to see the brand new ATS800 in action.

References

1. Hexagon. [Internet]. Available from: https://hexagon.com/

2. Leica Absolute Tracker ATS800. [Internet] Hexagon. Available from: https://hexagon.com/products/leica-absolute-tracker-ats800?utm_source=linkedin&utm_medium=organic-social&utm_campaign=global-2025-ats800-launch&utm_content=launch-video

3. Andreas Werner (2024) Advancing manufacturing with the Leica Absolute Tracker ATS800. [Internet] Hexagon. Available from: https://blog.manufacturing.hexagon.com/advancing-manufacturing-with-the-leica-absolute-tracker-ats800/

4. Hexagon accelerates large-scale aerospace inspection with laser tracking and direct scanning in one automation-optimised device (2025) [Internet] Hexagon. Available from: https://hexagon.com/company/newsroom/press-releases/2025/hexagon-accelerates-large-scale-aerospace-inspection-with-laser-tracking-and-direct-scanning-in-one-automation-optimised-device