Design for robustness and cost effectiveness: the case of an optical profilometer

The paper presents the design of an optical profilometer, a device used for the reconstruction of the micro‐geometry of mechanical parts in applications where high precision is needed. The design is based on Robust Design, a major methodology for quality improvement of engineering systems. Several design solutions, namely different hardware and software setups of the device, are compared in order to select a configuration realising a desired trade‐off between performance and cost. The peculiarity of the dsgin strategy is the use of a computer m odel of the measurement process where the physical part of the process is simulated. This allows for an extensive exploration of the design space, thus opening the way to product innovation.