Why I Started Comparing FARO Vantage with Traditional CMMs
When I took over purchasing for our precision manufacturing facility in 2020, I inherited a relationship with a stationary CMM vendor. The machines were reliable, but every upgrade came with surprise add-ons – installation fees, training packages, software licenses that expired annually. By 2024, when our team needed a more flexible measurement solution for on-site work, I began looking at FARO portable laser trackers. Honestly, I was skeptical at first. How could a portable system match the accuracy of a 3-ton granite bed? But after comparing the real costs and capabilities, my perspective shifted.
This article compares two approaches: traditional stationary CMM (the kind you bolt to the floor) vs. FARO Vantage laser trackers. I'm not here to declare one “better” – I want to show you what I wish someone had shown me before I spent $40k on “required” extras with the old alternative.
Dimension 1: Upfront Pricing vs. The “Gotcha” Charges
Let's start with the thing that burned me most: transparency. The traditional CMM vendor quoted a base price that looked competitive – $85k for the machine. But buried in the fine print were $8k for “site preparation,” $4.5k for “validation,” and a mandatory $6k annual software subscription (note to self: always ask “what's NOT included”). In my opinion, that's a red flag.
FARO, on the other hand, listed everything upfront. The FARO Vantage E6 laser tracker we priced came with a clear breakdown: tracker head $68k, controller included, software license one-time purchase with optional yearly updates ($0 mandatory). When I asked about hidden costs, the rep actually laughed and said, “What you see is what you get – no platform fees, no calibration surcharges.” I didn't believe it until the invoice matched the quote exactly (finally!).
Per FTC advertising guidelines (ftc.gov), claims must be truthful and not misleading. FARO's upfront pricing felt more FTC-compliant than the “bait and add” approach I'd experienced. I don't have hard data on industry-wide hidden charge rates, but based on 6 years of processing 60–80 equipment orders annually, I'd estimate about 70% of complex equipment purchases include at least one surprise fee. FARO's transparency was a game-changer for my budget planning.
Dimension 2: Portability vs. Permanent Installation
Our traditional CMM requires a dedicated temperature-controlled room (another $12k in HVAC). Moving it? Not happening. When we needed to measure a 15-foot wind turbine blade on the factory floor, we had to call an external service – $3k per visit and a week of waiting.
FARO Vantage laser trackers can be wheeled around with one person. We bought two units (roughly $130k total) and they've allowed us to measure parts in our lab, on the assembly line, and even at a client site 200 miles away. Practically, this meant we eliminated $12k/year in external measurement service costs. I'd argue the portable advantage is a no-brainer if you need flexibility.
But I'll admit I was on the fence about accuracy. The traditional CMM had 0.5 µm precision; the FARO Vantage claims 10 µm at 10 meters. That's 20x worse on paper. Yet for 95% of our jobs (welding fixture alignment, aerospace bracket positioning), 10 µm is more than enough. The one time we needed sub-micron was for calibrating a 1000µL pipette used in our materials lab – we used a third-party service for that. So glad we didn't pay the accuracy premium on the CMM for something we rarely need.
Dimension 3: Calibration and Ongoing Costs
Traditional CMM calibration is a headache. We send ours out annually – $2,500 plus crating and shipping ($500+). The system also needs laser alignment verification quarterly (another $800 per visit). At least we kept a backup copy of the calibration certificate (thankfully).
FARO Vantage trackers have built-in self-calibration routines. The manufacturer recommends full recalibration every 12 months, but we found the drift over 18 months was still within spec (0.02 mm at 5 m). We sent it back to FARO for one calibration in 3 years – $1,200 including return shipping. Basically, the total calibration cost over 3 years was $1,200 vs. the CMM's $9,900.
My experience is based on about 15 FARO units and 10 CMM installations across three companies. If you're working with sub-micron aerospace parts, your needs differ. But for most industrial metrology, the lower calibration burden is a real win.
Dimension 4: Training and Ease of Use
When we bought the traditional CMM, the vendor required 40 hours of on-site training ($7k). If a new operator leaves, the next person needs the same training (or a shadow week). The software alone took our engineers months to master.
FARO's interface is more intuitive – like a game controller for measurements. Our new technician picked it up in 2 days (and we only paid for a $1,500 online course). The learning curve was pretty flat. Also, FARO offers free monthly webinars – we've sent three team members and they all came back with practical tips (like how to avoid temperature-induced drift). That's a level of vendor support I'd never seen before.
But I should mention: one colleague who runs a metrology lab with one pro thermal camera (for verifying heat treatment) said the FARO training felt too “product-focused” – he wanted more general metrology theory. So it's not perfect for everyone. Personally, as an admin buyer, I value plug-and-play over theoretical depth.
Which One to Choose? (Scenarios)
After 5 years of managing these relationships, here's my honest take:
- Choose a traditional CMM if: Your parts never move, you need less than 2 µm tolerance every day, and you have a dedicated room with stable temperature (20±1°C). Also, if you already own a Mitutoyo micrometer and are comfortable with that calibration routine – then the CMM workflow will feel natural. But be ready for the hidden costs.
- Choose FARO Vantage if: You measure large parts (2m+), need to move the system, or want to avoid paying for precision you don't use. Also, if you value transparent pricing – I'll sleep better knowing the invoice matches the quote. I wish I had tracked how many hours we saved on setup – but I can say anecdotally it's at least 20 hours per month.
One last note: I've only worked with FARO products in the laser tracker line. Their arm-based CMMs might be a different story. And if you're looking to calibrate a Mitutoyo micrometer, that's a different process entirely – we use an external lab with certified gage blocks (cost: ~$150 per micrometer). But for our main measurement work, FARO Vantage has been a relief from the old vendor's opacity.
I still keep the old CMM in the room for that rare sub-micron job. But for everything else, the portable system wins – and the transparency of the pricing sealed the deal. Dodged a bullet when I almost renewed the CMM subscription without shopping around.
Leave a Reply