Abstract: The method and system provide a means of inspecting die sets by scanning the core die and the cavity die separately. A special software technique is used to transform both data scans to the same coordinate system or frame in an orientation which simulates die closure. Then methods are used to determined the exact shape of the interior of the die set when closed.

Abstract: A method and system are disclosed for the automated alignment of free-form geometries. The method includes the steps of providing a computer work station, a first HDPDM describing the first geometry, and a second HDPDM describing the second geometry. The two geometries must be in crude alignment with one another within a coordinate frame. Next, a plurality of normal distances are computed from the first geometry to the second geometry. The normal distances are used to derive a weighted-fit objective function. A step size is then determined, and the step size is used in the following step of iteratively translating the second HDPDM until the objective function is maximized. The steps of determining a step size and iteratively translating the second HDPDM are repeated until the step size is less than or equal to a desired alignment resolution. The disclosed system includes the means for turning out the steps of the disclosed method.