001 · Automotive Plastics · Certainty AI

Automotive Plastic Part Inspection Perfected

From glossy painted fascia to textured interior panels, our AI-powered inspection ensures flawless finish and verified fit for every plastic component.

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LIVE · Plastic Inspection
VISION AI
Scratch
<50µm
Gap/Flush
±0.05mm
Cycle
10-45s
Status
PASS
002 · Turnkey Solution

Precision inspection for complex plastic parts

Combining advanced imaging, tailored lighting, and Certainty AI to detect defects at production line speeds.

Precision Imaging

High-resolution cameras with application-specific optics capture every detail, from micro-scratches to dimensional variations.

Tailored Lighting

Custom lighting geometry for each surface type—dome for glossy, dark-field for textures, polarized for chrome/PVD.

Certainty AI

Reflection-aware AI trained specifically on automotive plastics reduces false positives from specular highlights and texture grains.

2D + 3D Fusion

Combines high-resolution 2D imaging with structured-light 3D metrology for comprehensive dimensional verification.

Multi-Axis Motion

Rotary/tilt tables and robotic rails eliminate blind spots on complex geometries with deep ribs and undercuts.

Digital Quality Certificates

Each inspected part receives a traceable DQC with annotated defect snapshots and measurement values.

003 · Why Plastic Parts Are Hard

Challenges & the Intelgic approach

Inspection Challenges

  • Complex geometry with deep ribs, clips, bosses, and undercuts create shadows and occlusions
  • Diverse finishes from high-gloss paint to textured matte each require different optics
  • Specular glare on glossy/plated surfaces hides micro-defects while low albedo black plastics reduce contrast
  • Color/texture variation across lots and warpage that distorts geometry
  • Mixed assemblies with inserts, gaskets, and lightguides requiring multi-modal checks

The Intelgic Approach

  • Lighting matched to surface & shape: dome/coaxial for glossy, dark-field for sleeks, polarized for chrome
  • Multi-camera, multi-angle coverage with robotic motion to eliminate blind spots
  • 2D + 3D fusion combining appearance inspection with dimensional verification
  • Reflection-aware AI trained on automotive plastics to reduce false positives
  • Custom machine vision design per part based on your CAD and tolerances
004 · Technology

System architecture

Imaging Hardware

  • 12-65 MP global-shutter cameras with HDR
  • Telecentric lenses for metrology; macro for micro-defects
  • Liquid lens for rapid autofocus across height changes
  • Structured-light or laser triangulation for 3D

Lighting Geometry

  • Dome + coaxial for high-gloss paint
  • Low-angle dark-field for sleeks & micro-scratches
  • Polarized bright-field for chrome/PVD
  • Diffuse bars/rings for textured matte surfaces

Motion & Fixturing

  • Rotary/tilt tables for multi-angle coverage
  • Robotic rails or cobot-mounted cameras
  • Encoder-synced conveyors for inline inspection
  • Soft nests and quick-change tooling

Certainty AI

  • Recipe-based inspection per color/texture
  • Reflection-aware segmentation
  • Texture-adaptive thresholds to avoid false calls
  • 2D/3D data fusion for gap-flush and warpage

Integration

  • PLC/robot, MES/ERP via OPC-UA, Modbus/TCP
  • CAD import for measurement plans
  • Barcode/RFID for genealogy tracking
  • Dataset export for BI tools

Digital Quality Certificate

  • Traceable, shareable quality records
  • Annotated defect snapshots
  • Measurement values (gap-flush, color ΔE)
  • Operator/station traceability
005 · Inspection Strategies

Optimized for every surface type

Glossy Painted

  • › Dome + coaxial base imaging
  • › Low-angle dark-field for sleeks/nibs
  • › Cross-polarization to control glare
  • › Detects <10 µm scratches

Textured Matte

  • › High-power diffuse bars
  • › Texture-aware AI algorithms
  • › Grain uniformity assessment
  • › Distinguishes defects from texture

Chrome / PVD

  • › Polarized bright-field imaging
  • › Controlled illumination angles
  • › AI trained on specular reflections
  • › Detects pinholes ≥20-40 µm

Transparent

  • › Transmission/backlight imaging
  • › Oblique illumination for weld lines
  • › Uniformity mapping for diffusers
  • › Edge defect detection
006 · Quality Assurance

Defects & checks we cover

Molding & Material

  • Short shot, sink marks, voids/bubbles
  • Burn marks, splay, weld/knit lines
  • Flash, gate vestige, ejector pin marks
  • Flow lines, material contamination

Painting & Coating

  • Orange peel severity, dust nibs
  • Fisheyes, runs/sags, craters
  • Color ΔE and gloss/haze consistency
  • Coating coverage and edge pull-back

Plating (chrome/PVD)

  • Blisters, peeling/delamination
  • Pinholes, streaks, contamination smears
  • Adhesion defects

Surface / Cosmetic

  • Micro-scratches, scuffs, dents
  • Abrasion, foreign particles, stains
  • Surface contamination

Dimensional & Assembly

  • Hole/slot presence & position
  • Clip/boss integrity; insert presence
  • Gap & flush relative to mating features
  • Warpage/sag; overall contour

Labeling & Marking

  • OCR/OCV for part/lot IDs, symbols
  • Laser marks verification
  • Label presence/alignment/print quality

Lighting Components

  • Scratches, inclusions in lenses
  • Welding seam quality
  • Diffuser uniformity
  • Prismatic feature verification
007 · Applications

Typical parts & areas

Exterior

  • Bumper fascia
  • Grills, mirror housings
  • Wheel arch trims, spoilers
  • Rocker panels

Interior

  • Instrument panels
  • Center consoles, door trims
  • HVAC vents, pillar trims
  • Seat components, switch bezels

Lighting

  • Headlamp/tail-lamp housings
  • Lightguides, reflectors
  • Lenses, diffusers

Under-hood / EV

  • Reservoirs (coolant/washer)
  • Covers, ducts
  • Battery pack plastics
  • Clips & brackets
008 · Benefits

Why choose Intelgic?

Our specialized approach delivers measurable improvements in quality and efficiency.

Higher First-Pass Yield

Catch defects earlier in production, reducing rework loops and improving overall equipment effectiveness (OEE).

Lower Warranty Costs

Prevent defective parts from reaching customers, reducing warranty claims and brand reputation damage.

Data-Driven Improvements

Defect pareto analysis and trend monitoring help identify root causes for continuous process improvement.

Reduced Inspection Time

Automated inspection at line speed eliminates manual inspection bottlenecks.

Digital Quality Records

Traceable Digital Quality Certificates (DQC) support quality audits and compliance requirements.

Customized for Your Needs

Each system is designed for your specific parts, tolerances, and production requirements.

009 · Performance

Inspection capabilities

Detection Sensitivity

  • › Micro-scratches <10 µm (painted/glossy)
  • › Dust nibs ≥20-30 µm
  • › Weld/knit lines, flow lines, splay visibly flagged
  • › Plating pinholes ≥20-40 µm

3D Metrology

  • › Gap & flush repeatability ±0.05-0.10 mm
  • › Warpage maps to ±0.1-0.2 mm depending on FOV

Throughput

  • › 10-45 s/part in rotary/multi-view cells
  • › Conveyor lines up to 60-120 parts/hour per lane
  • › Performance varies with part size, finish, and coverage
010 · FAQ

Frequently asked questions

Yes. Dome/coaxial with cross-polarization provides uniform, glare-controlled images; AI is trained to ignore residual highlights.
Our models are trained on texture libraries and use adaptive thresholds with frequency/contrast cues to separate grains from true defects.
Yes. 3D structured-light/laser triangulation provides gap-flush maps; results are compared against CAD/nominals and included in the DQC.
Recipe management stores per-color exposure/thresholds; auto-exposure/focus helps switch-overs.
Yes. We support PLC/robot interfaces and provide cells for manual, semi-auto, and fully automated lines.

Solution

Industrial AI

LEGAL

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

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