We used the profile projectors strictly for profiles such as trapezoidal segment shapes of aluminum wires drawn and rolled for trapezoidal ACSR or rolled copper segment shapes for conductors for LPOF conductors. (Checked against ink drawn profiles on transparent film.) These profile projectors were on the plant floor and certainly could be used to accurately measure insulation thickness samples of reasonable size. (Not the small insulation thickness on say telephone wire.)
Metallurgical microscopes were found in laboratories or offices as all available drawing machine wire breaks were identified and saved. A separate base with a steel pin was also available so that small gauge insulation thicknesses could be accurately measured.
I really think the two instrument solution is the best but you may find that you can get by with only one. See if your supplier will give you a "loaner" of each for say a one month test period so you can determine which is the best solution for you and your plant.
Peter J. Stewart-Hay
Stewart-Hay Associates www.Stewart-Hay.com
519 641- 3212