How a leading autonomous vehicle manufacturer achieved sub-millimeter accuracy in sensor fusion using our custom 3D marker-based calibration system
A major automotive manufacturer developing Level 4 autonomous vehicles faced critical challenges in achieving accurate sensor fusion between their 128-channel LiDAR systems and high-resolution camera arrays. The existing calibration methods were time-consuming, required specialized facilities, and couldn't maintain accuracy in production environments.
CalibWorks developed a revolutionary 3D marker-based calibration solution that transformed their entire calibration workflow, reducing calibration time from hours to minutes while achieving unprecedented accuracy levels required for safe autonomous operation.
Complex sensor fusion requirements in production environment
Sub-millimeter precision needed for safe autonomous operation with zero tolerance for calibration drift over vehicle lifetime.
Existing methods took 4+ hours per vehicle, creating bottlenecks in production lines and limiting throughput.
Calibration needed to work across temperature ranges from -40°C to +85°C and various lighting conditions.
Synchronizing 8 cameras, 4 LiDARs, and 12 radar units with different update rates and data formats.
Solution needed to scale across multiple production facilities with minimal training requirements.
Regulatory compliance required comprehensive documentation and validation of every calibration.
Revolutionary 3D marker-based calibration system
We developed a comprehensive calibration ecosystem combining our proprietary 3D marker technology with advanced computer vision algorithms and machine learning-based optimization.
The solution features our patented retroreflective markers that are simultaneously visible to both LiDAR and cameras, enabling precise correspondence matching across sensor modalities.
From proof of concept to production deployment
Conducted comprehensive analysis of sensor configurations, production constraints, and accuracy requirements. Developed custom simulation environment to validate approach.
Built initial prototype with custom 3D markers and calibration algorithms. Achieved proof of concept with 0.1mm accuracy in controlled environment.
Deployed pilot system in single production facility. Calibrated 500 vehicles with continuous refinement of algorithms and procedures.
Rolled out to all 15 production facilities worldwide. Trained 200+ technicians and established 24/7 remote support infrastructure.
Transformative impact on production and quality
Advanced technology powering the solution
CalibWorks' solution has been transformative for our autonomous vehicle program. The accuracy and speed improvements have not only reduced our production costs but have significantly enhanced the safety and reliability of our sensor fusion systems. Their team's expertise and support throughout the implementation were exceptional.
Let our experts develop a custom calibration solution tailored to your specific sensor fusion requirements.