AI die ovality measurement
Your die stopped being round three shifts ago.
Average diameter passes. Ovality does not. MeasureMaster reads a full 360° geometry profile from a single image — Dmax, Dmin, ovality, circularity and a confidence figure — on optics you already own.
- Angular sampling
- 360° continuous
- Edge resolution
- Sub-pixel
- Reported form
- Ovality & circularity
- Data export
- CSV, per angle
Deployed against
The Problem
Wear does not announce itself
Nobody watches a bore go elliptical. They see the scrap it produces, days later.
Wear Is Invisible Until It's Expensive
Drawing dies wear unevenly. The bore slowly becomes elliptical, and the wire it produces inherits that shape — oval cross-section, inconsistent resistance, failed annealing, rejected coils.
Manual Gauging Is Slow and Subjective
A micrometer gives you two numbers at two angles picked by hand. Real ovality lives in the angles nobody measured. Two operators, two answers, no audit trail.
Lab Instruments Cost a Fortune
Dedicated optical die-measurement machines run into tens of lakhs and sit in a QA room. Most Indian MSME plants simply cannot justify one — so the check never happens.
The Answer
Metrology from an image
Point a camera at the bore. The engine handles the geometry.
Sub-pixel edge extraction
The boundary of the bore or product is recovered at finer-than-pixel resolution, so accuracy is not limited by camera megapixels alone.
Full 360° diameter sweep
Instead of two hand-picked calipers, we measure diameter continuously around the whole profile and report Dmax, Dmin, mean, standard deviation and the exact angles where extremes occur.
AI interpretation, not just numbers
The system explains what the geometry means — is this uniform wear, single-sided wear, a chipped bearing, or a chatter artefact — and what to do next.
Auditable output
Every angle-by-angle reading is exportable as CSV with a confidence score, so QA has evidence, not opinion.
A perfectly round bore plots as a flat line. A two-lobe sine wave like this is the classic fingerprint of ovality — and the phase tells you where on the die the wear sits.
Process
Capture to signed-off report
Five stages, under a minute per die.
Capture
An industrial camera, microscope adapter or even a good phone macro shot captures the die bore or the round product. A calibration reference sets the microns-per-pixel scale.
Isolate
The engine locates the circular feature, rejects background, glare and tooling marks, and reconstructs a clean closed contour.
Measure
Diameters are swept across the full 360°. Best-fit circle and best-fit ellipse are computed, giving ovality, circularity and deviation at every angle.
Judge
Results are compared against your tolerance band. The system flags pass, watch or reject — and reports its own confidence in the measurement.
Act & Record
AI-written insight explains the wear pattern and recommended action. Everything is logged and exportable for traceability.
Why Us
Where we differ
Diameter gauges are common. Roundness at this price point is not.
Ovality-First
Most systems treat ovality as a by-product of diameter. We built the entire pipeline around out-of-roundness as the primary signal.
MSME-Affordable
Software-led, camera-agnostic. You do not buy a machine — you add intelligence to optics you can already afford.
Explains Itself
An AI layer converts raw metrology into plain-language diagnosis and corrective action, so a line supervisor can use it, not only a metrologist.
Built in India, For Indian Plants
Designed in Ghaziabad against the realities of Indian wire, fastener and tube units — dust, mixed lighting, mixed skill levels, thin margins.
Measure your own part
Upload a photograph of any round product or die bore and get a full ovality report in your browser. No installation, no sign-up.