How Zebra 3D Profile Sensors Differ and When Each Makes Sense
3D profile sensors play a key role in many industrial applications where precise measurement of shape, height, or volume is required, as well as surface inspection or real-time detection of fine manufacturing defects. They are commonly used in automotive, electronics, logistics, and automated quality inspection.
Our partner, Zebra Technologies, offers a range of 3D profile sensors under the AltiZ family, which is currently available in two variants: the original AltiZ and the newer AltiZ 4200. Although both sensors operate on the same laser triangulation principle, their design and intended applications differ significantly.
This article provides a clear overview of the differences between the two variants and helps with selecting the right sensor for a specific application.
Common Technical Foundation of the AltiZ Series
Both AltiZ and AltiZ 4200 are 3D profile sensors designed for inline industrial applications. Their operating principle is laser triangulation, where the sensor captures a laser line projected onto the object and converts its deformation into 3D data in the form of individual profiles, depth maps, or point clouds.
Both variants share several key features:
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GigE Vision interface with GenICam and GenDC support
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Power over Ethernet capability
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IP67 protection rating suitable for industrial environments
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Support for encoders and multiple triggering options
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Compatibility with Zebra Aurora software
From an integration perspective, both sensors are built on the same technical foundation. The key differences lie in sensor design and the nature of the generated data.
Zebra AltiZ: Focus on Robustness and Handling Occlusions
The original AltiZ is based on a dual-camera design with a single laser. This concept is intended to minimize issues related to optical occlusions, which commonly occur when scanning complex geometries, sharp edges, or deep structures.
The two cameras allow the sensor to capture information from different viewing angles and combine it into the resulting 3D data. As a result, the data remains stable and consistent even in applications where a single-camera solution might reach its limits.
AltiZ is typically used in applications where the priority is:
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scanning complex and highly contoured shapes
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reducing the impact of occlusions and shadowing
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robustness and reliability of 3D data
Zebra AltiZ 4200: A Newer Generation Focused on Detail and Speed
AltiZ 4200 represents a newer generation of 3D profile sensors within the AltiZ family. Compared to the original model, it uses a single-camera design, which has enabled a significantly more compact form factor while increasing both resolution and acquisition speed.
The sensor provides more than twice the number of points per profile and very narrow fields of view. This allows it to capture fine surface details and small manufacturing defects that may not be reliably detectable with lower point density.
AltiZ 4200 is particularly suitable for applications that require:
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high resolution and high point density
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precise inspection of fine details
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compact integration in space-constrained setups
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high-speed inline acquisition
Typical examples include inspection of adhesive and weld beads, inspection of electronic modules, or precise surface inspection of small components.
Technical Comparison of AltiZ and AltiZ 4200
For quick orientation, the main differences between the two sensors are summarized in the table below, based on manufacturer technical data. At AMV Technology, we are very familiar with this technology. We train on it, test it, and deploy it in real-world applications. Whether it is height or volume measurement, deviation detection, or other inspection tasks, this technology makes sense wherever a combination of speed, accuracy, and reliability is required.
| Parameter | AltiZ | AltiZ 4200 |
|---|---|---|
| Sensor design | Dual-camera sensor, single laser | Single-camera sensor |
| Scanning principle | Laser triangulation | Laser triangulation |
| Points per profile | 1,984 points | 4,224 points |
| Maximum acquisition speed | up to 11,000 profiles per second | up to 14,000 profiles per second |
| Data throughput | lower point density | more than 42 million points per second |
| Field of view (X FoV) | approx. 55–310 mm depending on model | 26–32 mm, 43–58 mm, or 70–93 mm depending on model |
| X-axis resolution | tens of micrometers depending on model | down to single-digit micrometers depending on model |
| Z range (measurement height) | up to 385 mm depending on model | 20–70 mm depending on model |
| Working distance | up to 185 mm depending on model | 60 or 100 mm depending on model |
| Network interface | Gigabit Ethernet (GigE Vision) | 2.5 Gigabit Ethernet (GigE Vision) |
| GenICam / GenDC support | Yes | Yes |
| 3D outputs | Profile, depth map, point cloud | Profile, depth map, point cloud |
| Triggering | Encoder, external, internal object detection, software | Encoder, external, internal object detection, software |
| Protection rating | IP67 | IP67 |
| Dimensions | 233 × 121 × 48 mm | 133 × 125 × 51 mm |
| Application focus | Robust 3D data, handling occlusions | Detailed 3D data, high speed, compact design |
Not About Better or Worse, but About the Right Choice
Although AltiZ 4200 offers higher resolution and speed, this does not mean that the original AltiZ has lost its relevance. In applications involving complex geometries and a higher risk of occlusions, the dual-camera concept can still be the better option.
On the other hand, applications focused on fine details, high precision, and compact system design are often better served by AltiZ 4200. The key is always a correct evaluation of the specific application requirements.
How We Approach Selection at AMV Technology
At AMV Technology, we specialize in integrating machine vision into industrial applications. As a partner of Zebra Technologies, we not only supply AltiZ 3D profile sensors but, more importantly, deploy them in real production environments.
When designing a solution, we start with the specific application, its mechanical layout, required accuracy, and process speed. Based on this, we recommend the appropriate sensor variant and design its integration into the complete system.
If you are dealing with 3D inspection, measurement, or surface inspection and are unsure which AltiZ variant makes sense for your application, we will be happy to discuss it with you and propose a suitable solution.
Team AMV
