Gap & Flush Measure panel gap and flush on every vehicle against your specification tolerances on the record, at operational speed. Schedule a Demo arrow_right_alt Inspection PRISM ADD-ON

Where Surface Inspection Stops And Specification Compliance Starts

Panel alignment is not something a camera sees the way a human eye does. A door can look perfectly flush in a high-resolution capture and still be out of specification by millimeters that matter to your customer, your OEM partner, or your claims department.

Total Vehicle Passport

Here is the operational gap we are talking about. Your PRISM footprint captures every scratch, every dent, every paint defect across the exterior surface. We give you a timestamped inspection record that follows the vehicle from the plant to the dealership. That record is the foundation. But surface capture is not the same as dimensional measurement. Identifying that a panel exists is not the same as confirming it meets specification.

Gap and flush variance is the quality category that falls between what visual inspection can document and what specification compliance demands. A panel gap that widens by two millimeters between the assembly line and the distribution center is not a scratch. It is not a dent. It will not show up in a standard damage report. But it will show up as a customer complaint, a warranty claim, or a rejected delivery at the other end of the supply chain.

That gap in your inspection record is what the Gap and Flush Scanner was built to close.

Gap & Flush Scanner

The Gap & Flush Scanner measures gap and flush across every panel seam on every vehicle that passes through it, at the operational speed of your inspection environment, and writes each reading into the Total Vehicle Passport alongside the exterior record from your base PRISM footprint. Every vehicle gets a documented dimensional record. Every panel seam has a measurement tied to its specification.

Measured to Specification. Written to the Record. The Gap & Flush Scanner deepens the one record every vehicle already has in the Total Vehicle Passport, adding panel fit to the exterior condition already captured.

Gap Measurement. The lateral spacing between adjacent panels, measured at every seam — doors, hood, trunk, and closures — and read against the tolerance defined for each joint on the vehicle.

Flush Measurement. The vertical alignment between adjacent panels, capturing whether each pair sits on the same plane. A depth measurement recorded at every seam and checked against your flush specification.

Operational Speed Capture. Measurement happens at the speed your environment already runs. The vehicle keeps moving, the line holds its takt, and the yard flow stays exactly as it is today.

In-Line Architecture. The scanner is positioned in the vehicle path of your inspection environment. Vehicles pass through it during normal flow, capturing panel fit within the same pass as exterior inspection.

All-Weather Operation. The scanner holds measurement quality through dust, temperature variation, and the constant wear of a high-traffic yard or production environment, operating in the conditions your operation already runs in.

Built For Operations

Not every operation needs gap and flush measurement. The operations that do know exactly why they need it.

Assembly Line Exit Inspection

OEM plants with specification conformance requirements at end-of-line know the cost of a vehicle leaving the facility with panel alignment outside tolerance. It is not just a cosmetic issue. It is a warranty exposure, a dealer rejection, and a quality audit finding rolled into one.

Vehicle Distribution Centers

VDCs receiving vehicles from multiple plants and multiple carriers face a different version of the same problem. Panel alignment variance that was within tolerance when the vehicle left the plant may not be within tolerance when it arrives at the distribution center.

Port and Compound Operations

Mobile inspection via PRISM Scan can happen anywhere in the logistics chain. The further from fixed infrastructure the inspection occurs, the less likely an existing VIN identification mechanism is available at the point of capture.

How It Works

The Gap & Flush Scanner is not a standalone measurement station you add to your workflow.

Assessment First

We study your existing footprint, your vehicle mix, your panel junction requirements, and the specific tolerances your operation needs to measure before we configure anything. The scanner that goes into your environment is calibrated to your vehicles and your specifications, not to a generic measurement profile.

Seamless Data Integration

Every measurement the Gap & Flush Scanner captures joins the same continuous, timestamped vehicle record as every capture from your base PRISM footprint. There are no parallel databases. No separate dashboards. No manual data reconciliation. When your quality team pulls up a vehicle's Total Vehicle Passport, the panel alignment data is right there beside every exterior capture.

Compatible Footprints

The Gap & Flush Scanner integrates with POD (dispatch yard), TUNL (assembly line), and ARCH (gate and transfer points). Compatibility depends on the specific footprint configuration and the physical environment of your deployment. We confirm compatibility during the assessment phase, before any installation work begins.

From Capture to Record

Every gap and flush reading the scanner captures is part of the Total Vehicle Passport — the continuous inspection record that follows every vehicle from the assembly line to the dealership. A panel-fit measurement at end-of-line joins the same record as the exterior condition captured alongside it, the undercarriage layer from the Underbody Scanner, the gate record at the compound exit, and the handoff record from PRISM Scan at the carrier transfer.

Schedule a Demo

Panel fit is part of the inspection record — a dimensional measurement written into the same passport as every other condition on the vehicle.

Assessment. We study your vehicle programs, your reference models, your defined seam sections, and the tolerance bands each model requires, so the scanner measures against the standard your engineering team already works to.

Integration. We position the scanner in the vehicle path of your existing PRISM footprint and synchronize capture to line movement, measuring gap and flush within the same pass as exterior inspection.

Configuration. We map every measurement section to your reference model and set the tolerance band for each seam by program and model year, so each reading is judged against its own defined limit.

Deployment. We install within your production schedule and calibrate against a known reference standard. The footprint keeps running throughout, and our team stays on-site until measurements hold to your specification.

The PRISM Footprint Family

The Gap & Flush Scanner is one of three inspection add-ons built for operations that need deeper coverage than the base PRISM footprint provides.

Gap & Flush Scanner

Gap & Flush Scanner

Measures panel alignment and fit against specification tolerances. For operations where dimensional conformance is a quality or claims category. You are here.

Underbody Scanner

Underbody Scanner

Captures undercarriage damage, foreign object intrusion, and underbody condition. For operations where undercarriage documentation is a material dispute category.

Dent Arch

Dent Arch

Delivers structural dent detection at a precision level that general capture arrays are not optimized to provide. For operations where dent detection is a material quality requirement.

KIOSK

KIOSK

Vehicle identification module (not an inspection scanner). Captures VIN data wherever no existing identification mechanism is in place, so every inspection record is reliably tied to the correct vehicle.

Frequently Asked Questions

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Gap and flush measurement checks how vehicle panels fit together. Gap is the lateral spacing between two adjacent panels; flush is whether those panels sit on the same plane. The PRISM Gap & Flush Scanner measures both at every seam — doors, hood, trunk, and closures — against your specification tolerances, and writes each reading into the vehicle's inspection record.