Published on: Mar 03, 2025
Written by: Soumen das
Metal sheets are widely used in automobiles, aerospace, construction, and various other industries, where surface quality is a critical factor in determining the usability of the material. Metal processing companies receive large sheets and perform operations such as slitting process, cut-to-length processing, and surface finishing before delivering them to customers.
Industries like automotive and aerospace are highly stringent when it comes to defect acceptance. Even minor defects such as scratches, pinholes, dents, and cutting defects can lead to product rejections, production delays, and financial losses.
To meet these strict quality standards, machine vision AI-powered Automated Optical Inspection (AOI) systems play a crucial role in automating defect detection, classification, and reporting.
In industries like automotive and aerospace, even tiny surface defects can compromise structural integrity, safety, and performance.
✔ Quality Standards Compliance: Defects larger than the acceptable threshold can cause rejections from customers.
✔ Structural Integrity & Performance: Scratches and dents may weaken metal sheets in applications like aircraft fuselage and automotive body panels.
✔ Manufacturing Efficiency: Undetected defects lead to waste, rework, and increased costs.
✔ Aesthetic Appeal: In industries such as appliances and consumer electronics, visible surface defects impact the final product's appearance and marketability.
Defect Type |
Description |
Common Occurrence |
Scratches |
Surface abrasions caused by handling, cutting, or rolling. |
Found in automobile panels, aircraft skins, and coated metal sheets. |
Pinholes |
Small holes caused by contamination or processing errors. |
Common in aluminum foils, steel sheets, and coated surfaces. |
Dents |
Indentations caused by impact, pressure, or improper handling. |
Found in automotive body panels, aircraft fuselage, and industrial metal sheets. |
Cutting Defects |
Irregular or rough edges after slitting or cutting. |
Found in cut-to-length metal sheets, coil slitting, and edge trimming operations. |
The size of the defect plays a key role in determining acceptability and severity.
✔ Standard Defect Size Ranges in Metal Processing:
💡 Intelgic’s Machine Vision AOI System is capable of detecting defects ranging from 0.20 mm to 2 mm, ensuring precise quality control in high-speed production environments.
Each customer or industry may have different defect acceptance thresholds. For example:
✔ Automobile Industry:
✔ Aerospace Industry:
📌 Custom AI Training: Intelgic’s AI-driven inspection system allows manufacturers to train the AI model based on their customer's specific acceptance criteria.
📌 Defect Severity Classification: The system categorizes defects based on size and flags sheets that exceed the defect threshold.
📌 Automated Reporting: Generates reports with defect distribution, severity level, and suggested corrective actions.
1. Dual-Sided Camera Installation for Complete Surface Inspection
2. High-Speed Line Scan Cameras for Continuous Monitoring
3. AI-Powered Defect Analysis
4. Defect Severity Mapping & Reporting
5. Integration with Manufacturing Execution Systems (MES)
Detecting and classifying defects on metal sheet surfaces is essential for maintaining high-quality standards in automotive, aerospace, and construction industries. Defects such as scratches, pinholes, dents, and cutting defects can vary in size and severity, impacting the final product's durability and performance.
Intelgic’s AI-powered Machine Vision AOI system provides a precise, automated solution to detect micron-level defects, classify them based on size and severity, and generate real-time reports to help manufacturers meet strict quality standards.
Contact Intelgic today to implement an AI-driven metal sheet inspection solution that ensures zero-defect manufacturing and optimized quality control!
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