How FARO’s Leap ST Scanner Is Shaping a Smarter Manufacturing Workforce

We all know the manufacturing sector is at a tipping point. New tools, new technologies, new expectations, and less time than ever to get it all right. As someone who talks to engineers, operators, educators, and innovators on a weekly basis, I’m no stranger to the buzz around digitization and workforce challenges.

But during my recent live webinar with Will Pitarello of FARO Technologies, something clicked. This wasn’t just another tech talk or demo. It was a reality check on what we actually need to be investing in if we want to build a smarter, stronger workforce.

Starting with Why: What Problem Are We Trying to Solve? 

Let’s be honest—manufacturers are juggling chainsaws right now. Onboarding new hires, retaining senior talent, running lean operators, hitting quality benchmarks, and somehow prepping for the next wave of innovation. 

That’s a lot. 

The conversation with Will wasn’t centered around a pitch. It was centered around a question: How do we help people do their jobs better, faster, and with more confidence, even if they’re brand new to the floor? 

Because the workforce isn’t just stretched thin. It’s fraying at the edges. Tribal knowledge is walking out the door, and we’re not replacing it fast enough. 

What Is the FARO Leap ST and Why It Matters

The FARO® Leap ST® handheld 3D scanner isn’t just a new toy for your metrology lab. It’s a response to the friction points we’ve been complaining about for years: slow inspection times, lack of portable solutions, and outdated interfaces that require an expert to interpret results. 

Will broke it down into plain terms: this scanner is designed to be intuitive, efficient, and ready for real-life manufacturing conditions. It’s handheld and lightweight. It doesn’t require a complicated setup. It scans multiple materials, even reflective surfaces, without you needing to become a lightning technician. 

But the real kicker? It’s designed to empower people on the floor to make smart, confident decisions without needing an advanced degree in metrology. 

Closing the Skills Gap with Confidence, Not Complexity

One of my favorite moments in our chat was when Will explained how newer team members can start using the Leap ST with minimal training. That’s huge. 

Think about the training curve we usually see in quality inspection. You’ve got legacy systems that take weeks to understand. You’ve got specialists who are stretched so thin they can barely train someone before they retire. And you’ve got younger hires who are digital natives but frustrated by outdated tools. 

What Will described was something different: a handheld scanner that lets people scan a part, instantly see what’s in or out of tolerance, and even overlay scan data on CAD models. That’s not just faster—it’s empowering. Because when you remove the friction, people want to learn. They lean in. 

From the Shop Floor to the Classroom: A New Standard for Training 

Another angle that hit home for me was how the Leap ST fits into educational environments. Whether you’re running an apprenticeship program or a community college lab, the traditional metrology gear is often intimidating. It looks complicated. It feels complicated. So learners freeze up. 

But Will pointed out that the Leap ST isn’t just easy to use. It’s approachable. And when a tool feels approachable, it becomes a bridge instead of a barrier. 

Imagine students scanning a complex part and instantly seeing a 3D overlay. Imagine them learning GD&T concepts not from a textbook, but from a visual, hands-on experience that mirrors the real world. That’s not a dream; that’s already happening. 

Designing for Humans First, Then for Data

Will kept coming back to a theme that I absolutely love: human-centered engineering. It’s something I’ve been advocating for in every conversation I have. We can build all the smart tools in the world, but if they’re not built for the people who actually use them, they’re just expensive paperweights. 

The Leap ST was designed with the operator in mind. It’s ergonomic. It’s mobile. The interface is clean, the buttons are intuitive, and the feedback is immediate. That kind of usability isn’t a luxury. It’s table stakes for the next generation of tools. Because if we want people to adopt technology, they have to trust it. And to trust it, they have to understand it. 

Real Talk on ROI: It’s About Time, Talent, and Trust

We did talk numbers for a minute. And while ROI is important, the value of this kind of tool goes beyond dollars. Will put it best when he said that every minute you spend waiting for inspection results is a minute you’re not solving problems. 

With Leap ST, operators can run checks right at the workstation. No waiting for the quality team. No bottlenecks. No guessing. That’s a shift in culture as much as it is a shift in process. 

You’re telling your team, “We trust you with the tools to get this right.” That trust builds ownership. And ownership builds pride. And let’s be real, we could use a little more pride on the shop floor these days. 

Why This Matters for the Future of Manufacturing 

This conversation wasn’t just about a scanner. It was about showing up for the people who are still showing up for manufacturing. It was about making their jobs less frustrating, a little more rewarding, and a lot more impactful. 

Tools like the Leap ST aren’t replacing people. They’re reinforcing them. They’re saying, “We know this work is hard. Here’s something that makes it easier.” And when you remove unnecessary complexity, you free people up to focus on what really matters: quality, creativity, and growth. 

My Challenge to Leaders and Learners

If you’re reading this and you’re in a decision-making role, whether that’s in training, operations, or leadership, I challenge you to walk your floor this week and ask: Do our tools match the skill level and needs of our people? 

If the answer is no, it’s time to take a hard look at what’s available. Because we’re not just losing people to retirement or turnover. We’re losing them to frustration. To burnout. To inefficiency. 

I’m grateful to Will and the FARO Technologies team for showing up with solutions that actually make sense. This isn’t about flashy tech. It’s about functional tools that help us all move forward together. 

And if we want to close the skills gap, elevate our standards, and future-proof our workforce, it starts with what we put in their hands. 

That, to me, is the real leap.

Register for the play back here:  https://www.mavensofmanufacturing.com/watch-the-replay-faro-leapst.