MANUFACTURERS ARE DRIVING TOWARD INCREASED PROCESS AUTOMATION AND THE GOAL OF ZERO-DEFECTS. NEW AUTOMATED INSPECTION AND GAGING TECHNOLOGY IS REQUIRED FOR PROCESS VERIFICATION AND CONTROL. AS DEFECT RATES ARE LOWERED, MANUAL OR SAMPLED INSPECTION TECHNIQUES LIMIT THE ACHIEVEMENT OF PRODUCT QUALITY AND MANUFACTURING COST OBJECTIVES. PROPRIETARY SENSORS RESPONSIVE TO THE STANDOFF DISTANCE ARE COMBINED WITH LIGHT-BASED SENSORS WHICH DETECT CHANGES IN SILHOUETTE. THIS PRODUCES OPTIMUM MEASUREMENTS TO BOTH IN-PLANE AND OUT-OF-PLANE DIMENSIONS. SENSOR DATA IS FUSED AND ANALYZED TO PROVIDE ON-LINE INSPECTION AND GAGING OF CRITICAL PART DIMENSIONS.