First FMCW-based laser displacement sensors deliver sub-micron accuracy
29 April 2025 
Aeva, a Californian developer of next-generation sensing and perception systems, has announced the first laser displacement sensor to use a technology known as frequency-modulated continuous-wave (FMCW). This technology is claimed to deliver significant advantages over existing displacement sensors using traditional methods such as triangulation or time-of-flight.
The claimed benefits of the Eve 1D laser displacement sensors include:
- Precision vibration and velocity measurements The sensors can capture radial velocity accurately, expanding their uses to include vibrometry and velocimetry. They can, for example, measure the vibration of rotating parts such as fans and shafts, and detect the speed of moving parts such as conveyor belts.
- The ability to work across materials An ultra-high dynamic range delivers reliable precision when used with various materials and types of surface – reflective, transparent or dark – with seamless transitions and no artifacts.
- The ability to work in all lighting conditions The sensors are unaffected by ambient light or sensor interference, and can be used in any lighting conditions, including outdoors or in high-density sensing environments.
- Occlusion-free measurement A “unique” coaxial laser beam arrangement allows scanning in small clearance areas without occlusions or sensitivity to the scan direction.
The sensors can measure down to sub-micron levels and operate with target standoff distances from 100mm up to 20m, in a compact all-in-one form factor that combines measurement with data processing. They are claimed to outperform state-of-the-art displacement sensors with accuracies of 100 parts per million (0.01% linearity) and can operate at high speeds. These characteristics result in fast, precise inspection, high levels of throughput, improved quality control, and cost-effective manufacturing processes.
Manufacturers can use the sensors to measure the thickness, height, or position of components, monitor the velocity or vibration of moving parts, or check for flatness or warping.
Aeva says that laser displacement sensors are redefining precision measurements in production environments. They can measure the distance between the sensor and a target surface without physical contact, using a laser beam. They are designed for high-speed, non-contact operation, and can operate with accuracies down to the micrometer level – about 1/100th the thickness of a human hair.
The FMCW sensors are powered by Aeva’s CoreVision lidar-on-a-chip modules. They use the same silicon technology employed to ensure the strict reliability and durability requirements of automotive applications. The modules are built using silicon photonics to integrate key elements on silicon. Combined with Aeva’s proprietary sensing software, the Eve 1D sensors provide a scalable, software-defined product, that is free from the limitations of standard laser triangulation in terms of performance, cost and form factor.
“Built on the same core FMCW technology found in our Atlas automotive 4D LiDAR products, our Eve 1 line of sensors opens an entirely new market with significant revenue opportunity for Aeva,” says Mina Rezk, the company’s co-founder and chief technology officer. “Eve 1D delivers a unique combination of performance, cost and scalability, and addresses many of the drawbacks of today’s laser displacement sensor technologies. The sensors will help to increase quality control and precision as the global manufacturing industry becomes increasingly automated and reliant upon advanced sensor technologies.”
The new sensors are targeting a $4bn (and growing) global market for laser displacement sensors. They are designed for high-volume and inline automation applications, including factory and process automation, quality control, and precision manufacturing.
The first orders for the sensors have come from the German sensor-maker Sick and the Candian 3D scanning and inspection specialist, LMI Technologies. Between them, they have ordered more than 1,000 of the devices.
