Speed up industrial construction processes with LASER projection systems

In industrial construction, homes are manufactured in the factory and installed virtually turnkey on site. This construction process significantly reduces nitrogen and carbon emissions, both during production and during installation. Thanks to this approach, homes are wind and watertight within 10 days and completely finished within 50 days - a strong performance that combines speed with sustainability.

As recently as 2018, 4,346 housing units were built industrially, accounting for 7% of the total. In 2023, that number rose to 15,474 housing units - already 21%. An increase to over 21,000 housing units is expected for 2025, nearly 30% of total housing production. The number of industrially completed homes in the Netherlands is exploding - but how do we keep up the momentum and keep innovating this process?

The challenge in industrial construction: measuring, marking and molds

To maintain and further accelerate this growth, we need to work smarter. Less measuring and marking on the shop floor, and more preparation in the digital domain.

In practice, paper construction drawings are mostly used in the workplace.

Dimensions and markings are applied manually. Mechanical jigs and templates are still in wide use - a method of working that costs a lot of time, money and material. In addition, the risk of errors increases.

Specialists such as mechanics and assembly assembly workers spend much more time measuring and aligning than lifting or assembling. They stand on the shop floor with the working drawing puzzling over how the approach will be. Colleagues are called in to help measure, mark with pencil and align with a store hook - until one is ready to attach parts. Then those parts are placed in the marked spots and construction continues. It frequently happens that a precast element is laid out incorrectly, lies upside down or the working drawing is interpreted incorrectly. As a result, the element ends up on the construction site incorrectly and must be adjusted on site - a time-consuming and costly procedure.

Laser projection as a digital solution in industrial construction

What if industry could skip these manual measurements? What if we could project data from CAD files directly onto steel structures, precast elements or complex machine parts? Without physical templates, without measuring tapes, without guesswork.

With modern laser projection systems - such as the ZLP2 laser projector from Z-LASER - becomes a reality. This technology makes it possible to mark visual instructions and assembly lines directly on the workpiece with sub-millimeter precision.

Whether it is positioning drill holes or mounting points-the industrial construction process is accelerated, errors are prevented, and material and rework savings are achieved. Visual final inspection can even be integrated into the workflow, increasing the reliability of industrial construction production.

How does laser projection system in industrial construction processes work in practice?

When working with a laser projection system preparation shifts from the shop floor to the office. The technical draughtsman (BIM modeler or work planner) sets up the digital drawings so that they can immediately be used as projections in the production environment. In consultation with the mechanic (construction worker or assembly worker) it is determined how the parts must be assembled. This way the assembly starts immediately, accurately and without errors. The projector is placed on a tripod or attached to the wall/ceiling, and it projects a green laser onto the workpiece.

Predefining the assembly process digitally creates a streamlined workflow. This is ideally suited for repeatable tasks performed dozens or hundreds of times, as well as for custom work. Especially for unique projects, this approach maximizes shop floor time - with fewer errors, less waste and more control.
The projector is placed on a tripod or attached to the wall/ceiling, and it projects a green laser onto the workpiece.

The z-laser projectors can project in 3D. When the surface is above the workpiece, you can see the shape of the corner, bolt or hole. What's special about these systems is that you can add layers in the process. As long as you can properly align the projector with the barrel, you can project the image to a spot that is high in the air, so the welder or assembler can apply the part to the right spot.

Case study: laser projection at electrical installations in precast walls

A striking example of how laser projection speeds up and simplifies the industrial construction process can be seen in the installation of electrics in precast wall elements. In this application, pluggable systems are used: cables and sockets are delivered as ready-made components and clicked together. But despite this standardization, electrical installation remains complex, especially in walls with multiple groups - think of kitchen backsplashes with connections for oven, dishwasher, and boiling water faucet.

A mechanic is presented with a prefabricated element with sometimes as many as 8 to 19 styles, each with specific electrical connection points. From a drawing, he must determine exactly which cable should go where. A mistake means that the wall has to be opened in the workshop - a costly and time-consuming repair operation.

To avoid this, data from the digital work drawing is used and displayed on a screen at the workstation. A PC then controls a Z-LASER projector, which hangs above the station. This laser projects the exact electrical path onto the wall: where cables should run, where sockets and switch boxes should be located. The assembler follows the projected lines and assembles the components directly in the right place - "staying within the lines" literally applies here.

With open elements, most sockets are prepositioned. But with closed walls or two-sided elements, the exact position of the socket is not visible. Thanks to laser projection, the installer knows exactly where to lay the cable, so it can be easily picked up and connected later once the hole for the socket has been made.

This approach prevents errors, increases speed and ensures a streamlined workflow - a perfect example of how digital fabrication with Z-LASER takes industrial construction to the next level.

Integration with existing MES, ERP or automation system

Day-to-day application is simple. Export your CAD data to the easy-to-use ZLP Suite software. Then projection sequences and object positions can be determined. Your employees can then quickly switch between projections without physical templates or measuring tools.

Thanks to the open API interface, you integrate the ZLP projectors directly with your own MES, ERP or automation system. All projections are clearly visible to the human eye, thanks to optimized laser intensity and built-in safety features that comply with industry standards.

Specifically, what does LASER porjection in industrial construction provide?

• Save time: Less measuring and marking, faster assembly.
• Cost savings: Less material waste and rework.
• Precision: Submillimeter accuracy when projecting CAD data.
• Flexibility: Suitable for complex shapes and customization.
• Safety: Clear projections with built-in safety features.
• Integration: Link to your CAD, ERP or MES system via open API.
• Reliability: Robust design, long service life, IP65 certified.

The ZLP series is designed for use workshops, assembly halls and production lines. The compact and robust housing makes them suitable for harsh industrial environments.

Our experience as certified Z-LASER service engineers ensures fast and accurate installation, with minimal impact on your production. Perfect calibration of the laser in your specific operating environment gives you optimal performance and an edge in smart, error-free operations.

Want to discover how Sensor Partners can optimize your process? Simply schedule a free consultation at a date and time that suits you best! Contact our expert today for a free consultation.

Laser projection as part of Smart Assembly (Pro)

Sensor Partners offers a smart, modular solution to optimize industrial processes with real-time data and smart sensors. The application of Z-LASER projection systems connects seamlessly with our Smart Assembly (Pro) concept. Within this approach, sensor technology and advanced data analytics are used to improve processes - from construction to assembly and logistics.

Laser projection plays a key role here: it translates digital drawings directly into visual instructions on the workpiece, eliminating manual interpretation and errors. Combined with other sensors that measure position, movement or material throughput, for example, it creates a fully data-driven workflow. This leads to less waste, shorter lead times and higher product quality - scalable from individual workstations to entire factories.