Fourier Analysis in Production Metrology: Turning Measurement Data Into Process Insight

Why It Matters

Detecting periodic errors before parts leave the line cuts scrap costs and safeguards critical component performance, giving firms a competitive edge in high‑precision markets.

Key Takeaways

• FFT transforms raw measurement data into frequency spectra.
• Identifies vibration sources like tool wear, clamping instability.
• Enables early defect detection, reducing rejects and rework costs.
• Integrated in Mahr’s MarWin software across multiple measurement devices.
• Improves product quality for automotive, aerospace, medical sectors.

Pulse Analysis

Fourier analysis translates spatial measurement data into the frequency domain, allowing engineers to isolate periodic components that traditional profiling masks. The Fast Fourier Transform algorithm, now standard in metrology software, rapidly generates spectra where each peak corresponds to a specific vibration mode. This mathematical insight turns raw surface scans into actionable diagnostics, making it possible to pinpoint the exact frequency of a defect source and assess its amplitude relative to tolerances.

In a production environment, hidden vibrations stem from sources such as tool wear, unstable clamping, bearing degradation, or even neighboring machinery. By visualizing these frequencies, operators can differentiate genuine surface features from noise, schedule preventive maintenance, and adjust process parameters before a single part is rejected. Mahr’s integration of FFT into MarWin across devices like Mar4D PLQ, MarForm, MarSurf, and OptoSurf creates a seamless workflow: sensors capture data, the software computes spectra, and engineers receive instant, interpretable charts. The result is a measurable drop in scrap rates, lower re‑work costs, and enhanced reliability for high‑precision components used in automotive, aerospace, and medical applications.

The broader industry trend points toward data‑driven quality assurance, where real‑time spectral analysis becomes a standard checkpoint on the shop floor. As sensor technology advances and edge‑computing power grows, FFT‑based diagnostics will expand beyond periodic errors to detect subtle stochastic variations, further tightening tolerances. Companies that combine robust hardware with integrated software like Mahr’s MarWin gain a strategic advantage, turning vibration data into predictive insights that drive efficiency, reduce downtime, and sustain competitiveness in increasingly demanding markets.

Fourier Analysis in Production Metrology: Turning Measurement Data into Process Insight

February 19, 2026

In modern manufacturing, precision down to the sub‑micrometer range counts, and the demands on precision and quality are extremely high. Even the smallest deviations can affect the function, service life and noise development of components.

To detect such sources of error at an early stage and keep processes stable, measurement engineers use a method that at first glance has more to do with mathematics than with metal – Fourier Analysis. It makes it possible to identify quality risks early and avoid cost‑intensive subsequent errors.

Fourier analysis is a mathematical process that breaks down a measurement profile into its individual vibration components. Modern measurement software such as MarWin from Mahr calculates this analysis using a special algorithm, the so‑called Fast Fourier Transformation (FFT). It applies to all periodic profiles such as when the first and last profile points are identical. Fourier analysis is used particularly frequently for circular profiles, as it allows conclusions to be drawn about both the functional properties of the workpiece and the effects of production.

The result of the Fourier analysis is typically referred to as a spectrum and displayed as a bar chart. The horizontal axis shows the frequencies (number of wave crests), the vertical axis the amplitude (strength of the vibration). This provides a clear picture of the frequencies contained in the signal and their characteristics, giving users an objective basis for making decisions, initiating targeted measures, and efficiently rectifying process deviations.

Avoid Rejects – Reduce Noise – Eliminate Malfunctions

Vibrations can occur during the production of precision parts, for example due to unstable clamping, tool wear, bearing damage or external faults. These lead to periodic faults such as chatter marks or stripes on the workpiece surface. When machines vibrate or measuring systems register vibrations, these initially appear to be random noise. However, Fourier analysis turns this into a structured image: it shows which frequencies are contained and how pronounced they are. This allows workpieces to be characterized and, for example, the running and chattering noises of rotating workpieces to be predicted.

In production metrology this is especially relevant because the technician can now recognize influences in the measurement result, draw conclusions about the production process and improve it. The result is fewer rejects, reduced noise, prevented malfunctions and ultimately lower long‑term costs.

More Process Reliability – Fewer Rejects – Higher Product Quality

“Mahr measuring systems offer an easily executable integrated FFT function in the MarWin Professional measuring software.”

In the production environment, vibrations are the enemy of precision. Even the smallest vibrations—caused, for example, by running machines, tool vibrations, ambient noise or unstable clamping—can affect the production of workpieces or falsify measurement results. This can have serious consequences, especially for high‑precision components in the automotive, aviation or medical‑technology industries.

Fourier analysis helps by:

• Detecting periodic errors that could otherwise lead to malfunctions during use.

• Identifying sources of interference – it shows objectively whether a measuring station is truly vibration‑free and can pinpoint unexpected vibrations from neighboring machines or defects in the measuring system.

• Checking sensors – sensors themselves can generate faulty signals; Fourier analysis exposes such faults, creating process reliability and reliable measurement results.

Overall, Fourier analysis enables customers to plan production processes more efficiently, safeguard measurement results, improve product quality and reduce rejects.

Fourier Analysis: Understanding Frequencies, Ensuring Quality

“Evaluation using Fourier analysis makes it possible to detect precisely the vibrations that ‘stand out’. These vibrations cause functional problems and can usually be traced back directly to manufacturing influences.”

Fourier analysis has become an integral part of modern production measurement technology. It makes the invisible visible—namely vibrations that can have a major impact on workpiece function. For customers, this means greater process reliability, fewer rejects and higher product quality.

If you want to make good use of FFT data, you need the right combination of sensors, expertise and software, and that’s exactly what customers get from Mahr. Many measurement systems from the measurement‑technology specialist offer an easily executable integrated FFT function in the MarWin Professional measurement software, thus creating a valuable basis for predictive and controllable quality assurance – a decisive factor for economic efficiency and competitiveness.

Mahr offers Fourier analysis for

• Tactile measurements in the Mar4D PLQ cylinder coordinate measuring machines

• Form‑measuring devices of the MarForm series

• MarSurf devices for tactile roughness and contour measurement

• The OptoSurf series for optical surface analysis

For more information: https://metrology.mahr.com/