001 · Aerospace · Certainty AI

Aircraft Window & Windshield Inspection Automation

See safety, not just defects. Intelgic automates visual and dimensional inspection of aircraft transparencies with Certainty AI.

LIVE · Transparency Cell
VISION AI
Aircraft window inspection
Defect
<10µm
Cycle
2-6 min
Coverage
100%
Status
PASS
002 · Challenges

Why aircraft transparencies are uniquely challenging

Aircraft windows are transparent, curved, multi-layered, and highly polished — introducing inspection issues that standard systems miss.

Transparency Issues

Defects can vanish without the right illumination path and background control.

Glare & Reflections

Specular surfaces & AR/conductive coatings mask sleeks, pits, and stains.

Curvature Effects

Thickness gradients cause refraction and double imaging, shifting apparent defect positions.

Laminates & Interlayers

Hide sub-surface flaws (bubbles/seeds, delamination) unless lighting is carefully controlled.

Heater Wires

Conductive films add patterns that can be mis-classified as defects.

Edge Zones

Fastener zones & sealant boundaries are hard to illuminate and easy to miss.

003 · Intelgic Approach

Precision optics meets Certainty AI

Our solution combines precision optics, application-specific lighting geometry, multi-axis motion, and Certainty AI to detect micro-defects and validate geometry.

Custom Lighting Geometry

Matched to part size, shape, and layer stack with low-angle oblique bars, collimated backlight, and dome/coaxial illumination.

Reflection-Aware AI

Trained on aerospace datasets to ignore heater wire patterns and structured reflections while detecting true defects.

Microscopic Capability

Detects <10 µm scratches/pits on flats and ≈20-30 µm on large curved transparencies.

Intelgic Approach
004 · What We Inspect

Comprehensive defect detection

Across all critical areas of aircraft transparencies.

Surface & Coatings

  • Hairline scratches, sleeks, scuffs, digs/pits
  • AR/hard-coat defects: pinholes, streaks, haze
  • Contamination: paint overspray, sealant smears

Sub-surface & Laminate

  • Bubbles/seeds, inclusions, blisters
  • Early delamination indicators
  • Interlayer voids and anomalies

Geometry & Optical Quality

  • Outer contour, thickness mapping
  • Distortion/flow lines via deflectometry
  • Haze/scatter index maps
005 · System Architecture

Engineered for aerospace transparencies

Imaging Hardware

  • High-resolution area-scan (12-65 MP)
  • Telecentric lenses for metrology
  • Liquid lens for rapid autofocus

Lighting Geometry

  • Low-angle oblique/dark-field
  • Collimated/telecentric backlight
  • Coaxial bright-field/dome
  • Polarization kits

Motion & Fixturing

  • Multi-axis robotic rails/gantry
  • Rotary/tilt stages
  • Vacuum or soft-nest fixtures

Certainty AI Software

  • Recipe-based inspection
  • Reflection-aware segmentation
  • Real-time PASS/FAIL
  • Digital Quality Certificate
006 · Digital Quality Certificate

A tamper-evident record for every PASS

For every PASS transparency, Intelgic issues a digital, shareable, tamper-evident record of inspection results.

  • Part ID/serial, job/lot, timestamp
  • Annotated defect snapshots and locations
  • Defect list with type/size/severity
  • Measurement summaries and reason codes
  • Operator/station traceability
Digital Quality Certificate
007 · Technical Specifications

Performance & integration specs

Detection Capabilities

  • <10 µm on flat coupons
  • ~20-30 µm fine scratch/pit on curved windows
  • Bubbles/seeds ≥30-50 µm
  • Edge chips ≥20 µm length

Throughput

  • 2-6 minutes per window for full inspection
  • Faster for targeted re-inspection
  • Performance varies with material and curvature

Interfaces

  • OPC-UA, Modbus/TCP
  • Ethernet/IP, REST APIs
  • Barcode/RFID readers
  • Label/marking printers
008 · FAQ

Frequently asked questions

Yes. The AI is trained on heater wire geometries and uses frequency/shape cues to prevent false positives; low-angle dark-field isolates true micro-scratches.
Multi-angle and dual-side illumination accentuate interlayer anomalies such as bubbles, seeds, and early delamination for targeted review.
Optionally, a deflectometry module produces reflection-based slope/cosmetic maps to support process tuning and acceptance decisions.
With multi-axis rails/gantry and soft-nest or vacuum fixtures that stabilize the part while keeping optical surfaces safe.
Per-part DQC, shift/day reports, defect Pareto, and full audit logs with user actions; secure sharing for OEM/MRO stakeholders.

Head Quarter

17352 Murphy Ave Suite 101
Irvine, CA 92614
Phone: (949) 317-2420

Branch Office

5ES7-H, 5Th Floor, East Tower, Mani Casadona, Plot no -IIF/04, Action Area -IIF, Newtown, Kolkata-700160

Certificate

intelgic ISO 27001 certification

Social links

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