The laser diffraction is a robust and precise technique to monitor wire diameters in-line. However, classical Fraunhofer diffraction formulas are not appropriate for 3D object size determination. The Babinet's principle allow to use such formulas only for angles of diffraction that tend to zero. A real diffraction measurement necessarily takes a finite angular range (approximately 10 degree(s)) and therefore, an error will be introduced if using classical formulas. The exact electromagnetic formulation is not appropriate to deal with 3D objects in a simple way. On the other hand we observed a systematic overestimation of the diameter, even very small angle of observation, in other words, a small misfit with the Babinet's principle.
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