Micron-Level Defect Detection using AI powered AOI system

Detect defects ranging from 8 to 100 micrometers in size.

Micron-Level Defect Detection
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Defect detection in sensitive products, parts and components

When it comes to manufacturing small, sensitive components, precision is not just a requirement—it is a necessity. Defects at the micron level can compromise product integrity, leading to costly rework, customer dissatisfaction, and even safety risks. Intelgic’s state-of-the-art micron-level defect detection solutions combine advanced imaging technologies, AI-driven analysis, and automation to deliver unparalleled accuracy and efficiency.

Defect detection

Why Micron-Level Defect Detection Matters

Micron-level defects are often invisible to the naked eye but can have significant impacts on the performance and reliability of precision components. Industries like medical devices, automotive, aerospace, and electronics demand flawless parts, where even the smallest imperfection can lead to:

  • Product failures
  • Increased warranty claims
  • Reduced customer trust

Intelgic’s solutions address these challenges head-on, ensuring that every part meets the highest quality standards.

Our Technology: How It Works

Intelgic’s micron-level defect detection system leverages cutting-edge hardware and AI to detect even the smallest anomalies with speed and accuracy.

High-Resolution Imaging

  • Cameras: use industrial machine vision cameras and custom camera modules for complex solutions. Depending on the application, we choose line scan or area scan cameras. To detect micron-level defects, we use 8k or 16k cameras with proper lenses. The interface of the camera could be GigE, 10 GigE, or USB, depending on the application and project requirements.
  • Lenses: We carefully select the appropriate lens based on the camera and application. Options include fixed focal lenses, telecentric lenses, and autofocus lenses. Selection depends on factors like the field of view (FOV), working distance, and defect size. Lenses are chosen to match image format, resolution, and other critical criteria.
  • Lighting: Proper illumination is essential for detailed imaging to detect micron-level defects. High-intensity lights are used to illuminate the target object. Lighting options include bar lights (with lengths depending on the width of the surface), coaxial lights, and ring lights for smaller part inspection. A controller is provided to adjust lighting conditions in real time.

AI-Driven Defect Detection

  • Intelgic’s proprietary Live Vision AI software processes images in real-time, using advanced algorithms to identify defects at a micron scale.
  • Detects scratches, cracks, surface deformations, and other anomalies with unmatched precision.
  • Categorizes defects based on type, size, and severity for actionable insights.

Robotic Integration (When Needed)

  • For parts with complex geometries, our systems integrate robotic arms to capture images from multiple angles.
  • Ensures complete surface inspection, leaving no area unchecked.

Comprehensive Analysis

  • Single-shot or multi-shot image stitching for detailed analysis.
  • Results are displayed in an intuitive interface, allowing operators to take immediate action.

Key Features and Benefits

Unmatched Precision

Detects defects as small as a few microns, ensuring zero-compromise on quality.

Real-Time Insights

AI processes images instantaneously, providing immediate feedback and reducing downtime.

Customizable Solutions

Tailored to meet specific industry requirements, from component size to inspection speed.

Seamless Integration

Easily integrates into existing production lines, enhancing your workflow without disruption.

Scalable and Efficient

Handles high-volume production with ease, improving throughput while maintaining accuracy.

Cost Savings

Minimizes rework and rejects, reducing operational costs and increasing profitability.

Industries We Serve

Intelgic's micron-level defect detection systems are trusted by leading manufacturers across industries

Medical Devices

Medical Devices

Ensuring the safety and reliability of implants and surgical instruments.

Automotive

Automotive

Detecting imperfections in precision components like connectors and fasteners.

Aerospace

Aerospace

Maintaining the integrity of mission-critical parts.

Electronics

Electronics

Inspecting PCBs and microchips for flawless performance.

Metal and Steel

Metal and Steel

Detecting surface defects in sheets, pipes, and structural components.

Glass Surface

Glass Surface

Detecting cracks, chips, and surface imperfections.

Plastic and Films

Plastic and Films

Ensuring uniformity and defect-free surfaces.

Coating and Color Surfaces

Coating and Color

Verifying the consistency and quality of painted or coated finishes.

Coating and Color Surfaces

Leather Surface

Ensuring consistent texture and quality in leather goods.

Coating and Color Surfaces

Aluminium Surface

Identifying scratches and inconsistencies in aluminum components.

Coating and Color Surfaces

Phone Components

Inspecting housings, screens, and internal parts for perfection.

Why Choose Intelgic

Why Choose Intelgic?

Expertise in Machine Vision

Our team has years of experience designing and implementing vision systems for complex applications.

Proprietary AI Software

Intelgic's Live Vision AI software is purpose-built for high-precision defect detection.

Customized Solutions

We work closely with clients to deliver tailored systems that meet their unique challenges.

End-to-End Support

From hardware selection to installation and ongoing support, Intelgic provides a complete solution.

Let's Elevate Your Quality Standards

Achieve flawless manufacturing with Intelgic's micron-level defect detection solutions. Whether you need to inspect thousands of parts per hour or detect the tiniest imperfections, we have the technology and expertise to make it happen.

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