001 · Web Inspection · Certainty AI

Transparent Plastic Sheet & Film Inspection Automation

Detect pinholes, gels, inclusions, and surface defects on transparent plastic webs with line-scan vision, transmission lighting, and Certainty AI.

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LIVE · Web Inspection
VISION AI
Transparent plastic sheet inspection
Defect Size
<50µm
wide sheet
2 Meter
Speed
500 MPM
Inspection
100%
002 · Compatible Materials

Compatible with all major plastic types

PET
PETG
PC
PMMA
PA
PP/PE
PVC
COP/COC
003 · Transparent Plastic Inspection

Why transparent sheets/films are hard — and how we solve it

Common Pitfalls

  • Transparency

    Defects disappear without the correct light path/background.

  • Low contrast

    Gels, fish-eyes, inclusions, and pinholes often blend into the scene.

  • Specular glare & web flutter

    Reflections and vibration cause false alarms and blur.

  • Thickness & birefringence variations

    Brightness/strain patterns mimic defects.

  • Coatings & laminates

    Add haze, streaks, and interface bubbles.

Intelgic Approach

  • Transmission lighting matched to task

    Collimated/telecentric backlight for pinholes; diffuse transmission for thickness mapping.

  • Surface lighting

    Low-angle dark-field for scratches; coaxial/dome with polarization to suppress glare.

  • Polariscopy (optional)

    For stress/birefringence visualization on PC/PMMA.

  • Web engineering

    Encoder sync, anti-flutter rollers, vibration-tolerant exposures.

  • Certainty AI

    Thickness-aware background models and streak/periodicity filters to minimize false positives.

004 · Technology

System architecture

Imaging Hardware

  • Line-scan cameras (2k-8k) for continuous web coverage
  • Telecentric lenses for metrology; high-NA macro for micro-defects
  • Liquid lens for rapid focus when switching thicknesses

Lighting Geometry

  • Telecentric/collimated backlight: pinholes, edges, silhouette
  • Diffuse transmission panels: gels, thickness/uniformity maps
  • Coaxial/dome with polarization: coated surfaces, glare control

Controllers & Software

  • Industrial PCs with GPU acceleration
  • Certainty AI with thickness-aware background models
  • Defect classifiers for all common plastic defects

Inspection Strategies by Station

  • A

    Transmission (diffuse)

    Global uniformity & inclusions; thickness proxy map

  • B

    Transmission (telecentric)

    Pinholes, edge/tear detection, silhouette metrology

  • C

    Surface (low-angle dark-field)

    Sleeks, micro-scratches, die lines

  • D

    Coating QA (optional)

    Coaxial/dome with polarization for AR/HC/adhesive coats

Performance & Throughput

Detection capability

Pinholes
≥10-20 µm
Gels/specs
≥20-50 µm
Scratches
<50 µm

Web speed

Up to 80 m/min per lane (higher possible with reduced FOV and optimized optics).

Metrology

Width/edge stability & silhouette features; thickness uniformity as relative index.

005 · Quality Assurance

Defects we detect

Material / Extrusion

  • Gels, black/white specs, unmelt, contaminants, crystal haze
  • Fish-eyes, orientation streaks, splay, flow lines
  • Gauge/thickness non-uniformity (relative mapping)

Surface / Mechanical

  • Micro-scratches/sleeks, scuffs, dents/dings
  • Die lines, chatter marks, orange peel
  • Wrinkles, fold lines, web creases

Coating / Laminate

  • Haze increase, streaks, voids, wetting issues
  • Interface bubbles/seeds, delamination starts
006 · Digital Quality Certificate

Tamper-evident traceability for every roll

Each roll/coil or cut sheet receives a comprehensive quality certificate with complete traceability.

  • Roll ID/lot, start-stop timestamps, recipe & software version
  • Defect map with coordinates, type, and size/severity
  • Summary KPIs (defects/m², pinhole counts, streak length, uniformity index)
  • PASS/FAIL logic with thresholds; operator/station traceability; secure share links
DQC #2023-06-4872
PASS
Roll ID
PET-23-4872
Thickness
0.125mm ±5%
Length
1,842m
Defects/m²
0.8
Defect Map Criticality: Low
Pinholes
2
Gels
3
Scratches
0
007 · Industries

Typical lines & applications

Extrusion & Calendaring

PC, PMMA, PET, PVC sheets

Blown/Cast Films

PET, PA, PP/PE, multilayer barrier

Coated/Functional Films

Hard-coat, AR/AG, adhesive (PSA), release liners

Laminates

Displays, glazing, solar, packaging

008 · Details

Technical specifications

Cameras

  • › 2k-8k line-scan; optional 12-45 MP area-scan
  • › HDR/global shutter

Optics

  • › Telecentric 0.3-1.0×
  • › Macro up to 5×
  • › Liquid lens autofocus

Lighting

  • › Diffuse & telecentric/collimated backlights
  • › Low-angle dark-field bars; coaxial/dome
  • › Polarization; optional UV/NIR; polariscopy

Interfaces

  • › OPC-UA, Modbus/TCP, Ethernet/IP, REST
  • › Barcode/RFID; slitter/rewinder IO
009 · FAQ

Frequently asked questions

Yes. Diffuse transmission creates calibrated intensity maps; AI models subtract expected thickness gradients to highlight true inclusions and gels.
Encoder-synchronized exposure, short strobe pulses, anti-flutter rollers, and vibration-tolerant processing maintain sharpness.
Yes. The web map includes lane coordinates so slitters/rewinders can avoid defect bands or trigger auto-markers.
Coaxial/dome with polarization elevates coating pinholes, haze, and streaks; we can also monitor uniformity trends.
We provide relative haze/clarity indices inline; for absolute conformance (e.g., ASTM methods), we can integrate with off-line instruments and link results to the DQC.

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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