Common Misconceptions in Metrology—And What You Should Know Instead

Metrology is a cornerstone of modern manufacturing and engineering, yet it's often misunderstood—even by professionals who rely on it every day. From confusing resolution with accuracy to overlooking environmental effects, these misconceptions can lead to poor measurement decisions, wasted time, and costly rework.

In this article, we’ll break down:

• The most common metrology myths

• Why they persist

• What the correct understanding should be

• How to train your team to avoid critical errors

Misconception #1: “High Resolution Means High Accuracy”

The Myth: A high-resolution scanner or measurement system must be highly accurate.  The Reality: Resolution only refers to the smallest detail your system can detect—it does not indicate how close your measurement is to the true value.

Think of it like using a high-resolution camera with a blurry lens: you get a detailed image, but it’s not necessarily accurate.

The Fix: Evaluate accuracy independently of resolution. Ask for third-party accuracy certifications or test the system on known reference artifacts.

Misconception #2: “Repeatability Equals Accuracy”

The Myth: If I get the same result every time, the system must be accurate. The Reality: A system can be highly repeatable and still be consistently wrong. Repeatability means consistent results, not correct ones.

The Fix: Incorporate accuracy checks into your process using certified standards, such as gauge blocks or calibration artifacts. Combine repeatability with trueness to verify overall system performance.

Misconception #3: “The Software Will Fix Everything”

The Myth: Post-processing software can correct errors and make unreliable data usable. The Reality: Software can help with visualization, but it can't fix poor technique, misalignment, or improper calibration. Garbage in still results in garbage out.

The Fix: Train your team in proper data acquisition techniques. Understand how software filters, smoothing, and stitching work—and when they may be distorting your results.

Misconception #4: “If It Looks Right, It Is Right”

The Myth: A clean-looking color map means the part is within tolerance. The Reality: Visual data can be misleading. Even if a surface map looks smooth, the underlying numerical deviations might reveal significant issues.

The Fix: Always review the numerical deviation data alongside visual outputs. Ensure proper alignment methods are being used, especially when comparing scans to CAD or baseline parts.

Misconception #5: “All Scanners, Trackers, and Arms Are the Same”

The Myth: If two devices can scan parts, they are interchangeable. The Reality: Each type of metrology tool has unique capabilities and limitations.

Examples:

• A handheld 3D scanner is flexible and fast but may not hold tight tolerances.

• A laser tracker is precise over large volumes but sensitive to environmental conditions and line-of-sight interruptions.

• A portable CMM arm is accurate in short-range tasks but limited by reach and operator technique.

The Fix: Choose your equipment based on:

• Part size and geometry

• Tolerance requirements

• Operating environment

• Portability needs

• Team experience and training

If you're unsure, consult with a metrology expert before investing in new equipment.

Misconception #6: “The Environment Doesn’t Matter”

The Myth: Measurement results are consistent across all environments. The Reality: Environmental conditions like temperature, humidity, vibration, lighting, and part temperature significantly impact results.

The Fix:

• Perform measurements in temperature-controlled spaces when possible

• Use devices with thermal compensation features

• Conduct drift checks throughout the day

• Watch for floor vibrations, especially with trackers and arms

Misconception #7: “If It’s Calibrated Annually, It’s Good”

The Myth: A system is accurate as long as it was calibrated sometime in the past year. The Reality: Annual calibration is a starting point. Day-to-day accuracy can still drift due to temperature changes, rough handling, or software updates.

The Fix: Use interim checks with certified artifacts regularly. Implement a routine drift verification process—daily or weekly—especially before critical jobs.

Misconception #8: “The Operator Doesn’t Impact Results”

The Myth: The system handles the work—operators just run the software. The Reality: Operator technique has a major influence on measurement reliability. Errors in scanning angle, probe movement, and workflow execution can all affect results.

The Fix:

• Provide thorough and ongoing operator training

• Standardize workflows and inspection routines

• Review measurement data regularly as a team to identify inconsistent practices or technique issues

Why These Misconceptions Persist

These myths are often reinforced because:

• Sales demos showcase best-case scenarios

• Software can mask problems with smoothing or filtering

• Teams are rarely given long-term, hands-on training

• Calibration is treated as a checkbox instead of a process

How to Improve Measurement Integrity

To move past these misconceptions, take the following steps:

• Educate your team on the difference between resolution, accuracy, and repeatability

• Use certified reference artifacts for interim system checks

• Validate the software tools and alignment strategies you're using

• Build inspection templates with clear, repeatable instructions

• Invest in continuous training and workflow audits

Call to Action: Bring Clarity to Your Measurement Process

Don’t let misunderstandings compromise your quality, production speed, or budget. At SS Metrology Solutions, we offer:

• On-site training to correct measurement myths and build good habits

• Custom workflow audits to uncover hidden inefficiencies

• Expert consultations to help select the right tool for your needs

• Support plans to keep your team's skills sharp all year round

Book a training session or consultation today and get your team aligned with metrology best practices that deliver real results.