OptiPhi Solutions offers expert consulting and training in the field of metrology. With over two decades of industry experience, we help manufacturers strengthen their understanding of GD&T and advanced metrology principles. In addition, we develop customized software solutions to address specialized measurement and analysis requirements that standard tools cannot fully meet.
OptiPhi provides specialized training and consulting services that empower engineers and organizations to deliver accuracy, reliability, and efficiency in every project.
Design, inspect, and deliver parts that meet the highest global standards.
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We combine technical mastery with decades of global experience to solve complex metrology and manufacturing challenges.
Clients trust us for delivering solutions that directly translates to business growth and production efficiency.
Saurabh Vishal is an engineering leader with over 25 years of experience in Metrology, CAD, and CAE, dedicated to helping industries achieve new levels of precision and automation. His work blends mathematical insight with practical engineering expertise to solve complex manufacturing and inspection challenges.
A graduate in Mechanical Engineering from IIT Kanpur and NIT Warangal, Saurabh has played a pivotal role in advancing metrology software and automation across global industries.
During his 17 years at Renishaw, he led the development of Mathematical Metrology library for GD&T based on the ISO and ASME standards and has a thorough understanding of GD&T geometry and applications. He has created new technologies and devised more than 30 bespoke metrology solutions for leading companies in the aerospace, automotive, and consumer electronics sectors, including GM, Ford, Honda, and BMW.
Having worked with organizations across more than 15 countries worldwide, Saurabh continues to deliver innovative, mathematically robust solutions through diverse international experience.
Find answers to common questions about how OptiPhi Solutions’ consulting, training, and custom solutions help clients achieve precision with confidence.
Our clients include leading organizations across the aerospace, automotive, and electronics industries worldwide. To respect confidentiality agreements, we do not disclose all client names publicly. However, our expertise is demonstrated through collaborations with industry leaders such as BMW, Ford, GM, Honda, and numerous global aerospace and electronics companies.
OptiPhi offers unparalleled expertise through the creation of the Metrology Maths Library, developed over 14+ years for Renishaw, a global leader in inspection technology. Our differentiator lies in our deep understanding of GD&T standards, software, and underlying mathematics:
Internal Mechanics: We know exactly how GD&T standards and software function internally.
Fundamental Reasoning: Our training goes beyond the rules, explaining the reasoning behind each GD&T tolerance and drawing practice.
Subtle Insights: Years of developing the Metrology Maths Library have given us rare insights and nuanced understanding that few educators possess.
Practical Application: We focus on applying GD&T to achieve the largest possible functional tolerances in real-world design and manufacturing.
Hands-On Learning: Our workshops are highly interactive. Each participant learns through physical parts and personal artifact sets.
OptiPhi offers a distinct advantage in metrology through our deep, specialized expertise in the field.
Internal Knowledge of CMM Probes: With over 17 years at Renishaw, a global leader in inspection, we possess unique insights into the operation and performance of CMM probes, particularly Renishaw systems.
Optimization and Calibration: We understand the most effective methods for probe calibration and measurement to achieve maximum accuracy and repeatability.
CMM Software Expertise: Our experience developing measurement solutions and GD&T math libraries for Renishaw’s metrology products and modelling real-world gauge behavior in CMM software, enables us to provide expert guidance on optimal setup and utilization.
Absolutely. Software development is a cornerstone of our expertise. Our founder brings over 20 years of experience in software engineering, including leading a startup in photogrammetry.
Our most notable achievement is the creation of the Metrology Maths Library, a cutting-edge GD&T mathematics engine integrated into all of Renishaw’s metrology products.
We have also developed numerous inspection solutions and software tools, including automated planning systems that enable the measurement of complex geometries without human intervention. This expertise has been applied to deliver advanced solutions for leading aerospace, automotive, and electronics companies worldwide.
To measure a complex impeller blade and extract 3D cross-sections of the blade in a reliable, robust manner with the fastest possible cycle time.
The complete impeller blade was scanned using a 5-axis probing system. The required 3D scans were then mathematically extracted from the data with high accuracy, and a dedicated software solution was developed to support the process.
The solution was sold to one of the world’s largest aerospace companies, leading to hardware sales of 5-axis probing systems valued between 20 and 30 million dollars. It significantly strengthened relationships with key customers and reduced measurement time by 60%.
“I was able to download the results, and I have looked through them. Very nice. Everything looks really good. I think they would be useful tools for us.”
To replace physical gauges and manual effort used for checking the quality of API 5B threads with a custom software solution that requires neither physical gauges nor manual intervention.
The threads to be tested for dimensional accuracy were scanned using a tactile probe. The physical gauge was replaced with a mathematical one, and the tightening of the gauge by a human operator was simulated mathematically through the developed software.
The software solution was a breakthrough that revolutionized the thread industry, significantly boosting hardware sales and customer satisfaction. It led to hardware sales worth several million dollars. The need for expensive gauges was eliminated, reducing manual labor and providing a more repeatable and reliable solution.
“The customer is very much satisfied with the results. The customer said gauge with gauge measure data of 0.1mm deviation is normal. Thank you very much for your great support.”
To replicate the physical setup of aligning a crankshaft using two gauge spheres at its conical ends through a mathematical solution, where simulated spheres are fitted to measured data eliminating the need for expensive physical gauges.
A specialized software solution was developed to mathematically compute the centers of the end gauge spheres by measuring the conical ends of the crankshaft. Real physical gauges were not required.
The solution was sold to one of the world’s largest automobile companies, leading to hardware sales of 5-axis probing systems valued between 15 and 20 million dollars.
“We now use this method even when measuring cranks that have simple conical ends because we will get a fit that is not theoretical, but actual.”
To extract the actual dimensions of very small features connected to other features within a continuous measured dataset. These features, in the range of 100 to 150 microns, were almost impossible to extract using traditional techniques, such as a chamfer or fillet about 100 microns in size.
A single continuous scan was performed, capturing multiple features simultaneously. The features of interest were then mathematically extracted from the measured data using intelligent data fitting.
Many major international companies adopted this solution across China, Europe, and the USA. It helped us engage with key customers, driving hardware sales of nearly 25 million dollars and strengthening long-term customer relationships.
“Thanks for follow it up. With your support, we have measured those critical features and pass the GRR. The program itself is currently running at customer site and considered as a success. We would not be able to reach to this point without your team’s support. I would like to send our thanks to you and your team for your excellent support.”
To measure special valve seats that consist of two cones and one torus instead of the standard three-cone design.
A single continuous scan was performed, capturing multiple features simultaneously. The features of interest were then mathematically extracted from the measured data using intelligent data fitting.
Sold to a major automobile manufacturer that lacked a standard solution for the above special case. The software boosted the sales of CMMs and 5-axis probing systems.
“We got the project for a new automobile plant and expect the order this week. I want to say thank you to you and the whole team involved in this project’s success.”
To measure the minimum distance between two complex diffuser blades.
A bespoke software tool was developed to process curve scans and accurately determine the required distance between them.
Sold to a major aerospace company in India and to a US based manufacturer of special-purpose centrifugal pumps. The solution led to substantial hardware sales valued at a few million dollars.
“Thank you for the timely update on the software release. We truly appreciate your dedication in making this happen. A special thanks to the entire team that worked on releasing the software.”
To measure complex internal curves within parts using 5-axis probing systems. These curves pose accessibility challenges, making it very difficult to plan collision-free probe motions for accurate measurement.
A software application that automatically plans the required probe orientations and motion paths to measure curves using CAD model information. It ensures optimal metrology performance and delivers the fastest possible results.
A game-changing product, as planning complex curves through 5-axis probing systems is extremely challenging. It is used in over 30 countries and has generated more than 50 million dollars in business.
“I feel, it simply wouldn’t have been possible without using it! This proved a difficult challenge which the planner passed with flying colours. We now have a measurement solution that looks professional as well as being efficient by not coming on and off the surface because we couldn’t ‘hand craft’ a path through the normal tools.”
Challenge:
To extract the actual dimensions of very small features connected to other features within a continuous measured dataset. These features, in the range of 100 to 150 microns, were almost impossible to extract using traditional techniques, such as a chamfer or fillet about 100 microns in size.
Solution Provided:
A single continuous scan was performed, capturing multiple features simultaneously. The features of interest were then mathematically extracted from the measured data using intelligent data fitting.
Business Implications
Many major international companies adopted this solution across China, Europe, and the USA. It helped us engage with key customers, driving hardware sales of nearly 25 million dollars and strengthening long-term customer relationships.
Testimonials
“Thanks for follow it up. With your support, we have measured those critical features and pass the GRR. The program itself is currently running at customer site and considered as a success. We would not be able to reach to this point without your team’s support. I would like to send our thanks to you and your team for your excellent support.”
Technical Sales &
Marketing, Hong Kong
Challenge:
To replicate the physical setup of aligning a crankshaft using two gauge spheres at its conical ends through a mathematical solution, where simulated spheres are fitted to measured data eliminating the need for expensive physical gauges.
Solution Provided:
A specialized software solution was developed to mathematically compute the centers of the end gauge spheres by measuring the conical ends of the crankshaft. Real physical gauges were not required.
Business Implications:
The solution was sold to one of the world’s largest automobile companies, leading to hardware sales of 5-axis probing systems valued between 15 and 20 million dollars.
Testimonials
“We now use this method even when measuring cranks that have simple conical ends because we will get a fit that is not theoretical, but actual.”
Application Engineer, Major Automobile Company
Challenge:
To measure a complex impeller blade and extract 3D cross-sections of the blade in a reliable, robust manner with the fastest possible cycle time.
Solution Provided:
The complete impeller blade was scanned using a 5-axis probing system. The required 3D scans were then mathematically extracted from the data with high accuracy, and a dedicated software solution was developed to support the process.
Business Implications:
The solution was sold to one of the world’s largest aerospace companies, leading to hardware sales of 5-axis probing systems valued between 20 and 30 million dollars. It significantly strengthened relationships with key customers and reduced measurement time by 60%.
Testimonials
“I was able to download the results, and I have looked through them. Very nice. Everything looks really good. I think they would be useful tools for us.”
Application Engineer, US
Challenge:
To replace physical gauges and manual effort used for checking the quality of API 5B threads with a custom software solution that requires neither physical gauges nor manual intervention.
Solution Provided:
The threads to be tested for dimensional accuracy were scanned using a tactile probe. The physical gauge was replaced with a mathematical one, and the tightening of the gauge by a human operator was simulated mathematically through the developed software.
Business Implications:
The software solution was a breakthrough that revolutionized the thread industry, significantly boosting hardware sales and customer satisfaction. It led to hardware sales worth several million dollars. The need for expensive gauges was eliminated, reducing manual labor and providing a more repeatable and reliable solution.
Testimonials
“The customer is very much satisfied with the results. The customer said gauge with gauge measure data of 0.1mm deviation is normal. Thank you very much for your great support.”
Business Development Manager, China
Challenge:
To measure special valve seats that consist of two cones and one torus instead of the standard three-cone design.
Solution Provided:
A single continuous scan was performed, capturing multiple features simultaneously. The features of interest were then mathematically extracted from the measured data using intelligent data fitting.
Business Implications
Sold to a major automobile manufacturer that lacked a standard solution for the above special case. The software boosted the sales of CMMs and 5-axis probing systems.
Testimonials
“We got the project for a new automobile plant and expect the order this week. I want to say thank you to you and the whole team involved in this project’s success.”
Application Engineer, Germany
Challenge:
To measure the minimum distance between two complex diffuser blades.
Solution Provided:
A bespoke software tool was developed to process curve scans and accurately determine the required distance between them.
Business Implications:
Sold to a major aerospace company in India and to a US based manufacturer of special-purpose centrifugal pumps. The solution led to substantial hardware sales valued at a few million dollars.
Testimonials
“Thank you for the timely update on the software release. We truly appreciate your dedication in making this happen. A special thanks to the entire team that worked on releasing the software.”
Technical & Services Manager, India
Challenge:
To measure complex internal curves within parts using 5-axis probing systems. These curves pose accessibility challenges, making it very difficult to plan collision-free probe motions for accurate measurement.
Solution Provided:
A software application that automatically plans the required probe orientations and motion paths to measure curves using CAD model information. It ensures optimal metrology performance and delivers the fastest possible results.
Business Implications:
A game-changing product, as planning complex curves through 5-axis probing systems is extremely challenging. It is used in over 30 countries and has generated more than 50 million dollars in business.
Testimonials
“I feel, it simply wouldn’t have been possible without using it! This proved a difficult challenge which the planner passed with flying colours. We now have a measurement solution that looks professional as well as being efficient by not coming on and off the surface because we couldn’t ‘hand craft’ a path through the normal tools.”
Application Engineer, UK
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elit tellus, luctus nec ullamcorper mattis, pulvinar dapibus leo.
