Resolution in Metrology: What It Means and Why It Matters

When evaluating metrology systems—Laser Trackers, Portable Arms, 3D Scanners, or CMMs—one term pops up frequently in brochures and tech sheets: resolution. But what does it actually mean, and how does it affect your measurements?

Resolution is more than a marketing buzzword—it directly influences what your system can detect, measure, and report. In this post, we’ll unpack what resolution means in practical terms, how it differs from accuracy and repeatability, and how to make sure it aligns with your real-world applications.

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What is Resolution in Metrology?

Resolution refers to the smallest measurable unit or change a device can detect. In simple terms, it's the smallest movement or distance a sensor can pick up and report.

Examples:

• A device with 1-micron resolution can detect a 0.001 mm change in position.

• A 3D scanner with 0.05 mm resolution can capture surface details as fine as 50 microns.

📌 Important: High resolution doesn’t automatically mean high accuracy—just that the system can detect tiny changes or features.

Term	What is Means	Analogy
Resolution	Smallest detectable change or increment	A ruler with very small hash marks
Accuracy	How close a measurement is to the true value	How close your aim is to the bullseye
Repeatability	Ability to get the same result multiple times	Shooting the same spot over and over

You could have a high-resolution device that’s inaccurate (wrong target) or inconsistent (can’t hit the same spot twice).

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1. Fine Features & Complex Geometries

If you’re scanning small components with intricate surfaces—like turbine blades or dental molds—you need high resolution to capture every detail.

Example: A 3D scanner with 0.02 mm resolution can pick up sharp corners and small radii that a 0.1 mm system might blur or miss entirely.

2. Edge Detection in Inspection

In dimensional inspection, clearly identifying edges or intersections depends on resolution.

Low-resolution tools might round off sharp edges or misrepresent chamfers, leading to incorrect GD&T evaluations.

3. Reverse Engineering

Reverse engineering legacy parts requires faithful replication. A scanner with low resolution will lose fine texture or minor surface deviations.

4. Welds, Surface Flaws, and Wear Detection

High-resolution metrology systems can help identify early-stage cracking, pitting, or corrosion—critical in aerospace, energy, and heavy machinery.

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How to Evaluate a System’s Real Resolution

Marketing materials often quote best-case resolution, which may only apply under ideal conditions. Ask these questions:

• Is the resolution consistent across the volume?

• What resolution is achievable at working distance X?

• Does resolution degrade in dynamic scanning (e.g., handheld)?

• Is the resolution limited by the hardware or the software filters?

  
  

📌 Pro Tip: Ask for real-world resolution demos on parts similar to yours. A system that performs well on plastic test artifacts might struggle on oily, dark metal parts.

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Limits of Resolution in Practice

More resolution isn’t always better. Here’s why:

• Data Size: High-resolution scans generate massive point clouds and mesh files. If you don’t need the detail, this creates storage and processing headaches.

• Noise Sensitivity: High-resolution systems are more sensitive to environmental noise—vibration, lighting, airflow.

  
  

Operator Experience: Untrained operators may produce worse results with high-resolution tools if not handled properly.

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Finding the Right Balance: Resolution vs. Workflow

Ask yourself:

• Do you really need 20-micron resolution for your inspection?

• Will your team be trained to handle high-density data?

• Does your software support large file processing?

• Is the resolution meaningful in your tolerance range?

  
  

Example: If your part tolerances are ±0.5 mm, capturing data at 0.01 mm resolution may not improve outcomes—but it will slow you down.

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Still unsure what level of resolution you need? Don’t make the mistake of over-buying—or worse, under-investing.

At SS Metrology Solutions, we help businesses:

• Understand the true resolution required by their applications

• Evaluate and test systems before purchase

  
  

Train teams on how to maximize device capabilities

Book a free consultation or training session today, and let’s make sure your resolution supports your real goals—not just marketing specs.