Full-Stack Integration Expertise
We engineer every layer of the inspection system — optics, cameras, AI, edge hardware, controls, and analytics — integrated and delivered as one.
Seven Layers of Integration
A complete inspection system spans from material handling to analytics. We own every layer.
Material Handling
Conveyors, feeders, diverters, reject mechanisms
Optics & Lighting
Lenses, ring lights, bar lights, backlights, filters
Image Acquisition
Area scan, line scan, 3D cameras — GigE, USB3, MIPI
AI Processing
Deep learning inference — defect detection, classification, measurement
Edge Hardware
NVIDIA Jetson Orin, industrial PCs, GPU compute
Controls & I/O
PLC integration, reject gates, pass/fail signals, line speed sync
Analytics & MES
Real-time dashboards, trend analysis, MES/SCADA connectivity
Optical Engineering
Lenses, lighting, and illumination design
Every inspection system starts with optics. We select and configure the optimal combination of lenses, lighting, and filters for each application — ensuring sharp, high-contrast imaging that makes AI detection reliable.
Lens Selection
- Fixed focal length (6mm–75mm, up to 20MP)
- Telecentric lenses for dimensional measurement (< 0.1° telecentricity)
- Macro & close-up for solder joints, micro-cracks, particles
- C-mount, CS-mount, F-mount options
Lighting Systems
- Ring lights for shadow-free surface inspection
- Bar lights for line-scan and wide-field conveyor setups
- Dome lights for diffuse, glare-free imaging on reflective surfaces
- Backlight panels for silhouette inspection and foreign object detection
- Strobe synchronization with camera triggers (down to 10μs)
Camera Integration
Multi-brand, multi-protocol camera expertise
We evaluate and select the best-fit camera for each application — based on resolution, speed, spectral response, and form factor. No vendor lock-in: we integrate cameras from all major manufacturers.
Supported Interfaces
- GigE Vision — long-distance, multi-camera setups over Ethernet
- USB3 Vision — high-bandwidth, low-latency for close-range
- MIPI CSI-2 — compact embedded cameras for edge-native systems
- Camera Link — ultra-high speed for specialized line-scan
Camera Partners
- Basler, FLIR / Teledyne, Hikvision
- Allied Vision, IDS Imaging, Ximea
- Area scan, line scan, and 3D profiling cameras
AI & Deep Learning
Purpose-built models for manufacturing inspection
Our AI models are trained on real production data — not generic datasets. We develop, train, validate, and deploy deep learning models purpose-built for each inspection task.
Core AI Capabilities
- Defect detection — classify and localize surface defects, contamination, anomalies
- Dimensional measurement — non-contact gauging with sub-pixel accuracy
- Classification & sorting — multi-class by color, shape, size, grade
- Anomaly detection — unsupervised models for previously unseen defect types
- OCR & code reading — text, barcodes, QR, data matrix for traceability
Training & Validation
- Custom model training on your production samples
- Iterative validation with real reject/pass data
- OTA model updates without production downtime
Edge Computing
On-premise inference with zero cloud dependency
All AI inference runs on-premise using industrial-grade edge hardware. No data leaves your facility, no internet dependency, no latency — just production-speed processing connected directly to your controls.
Edge Hardware
- NVIDIA Jetson Orin / Xavier NX — GPU-accelerated inference
- Industrial PCs with dedicated GPUs for multi-camera workloads
- Industrial temperature range and ruggedized enclosures
- Multiple camera streams on a single edge device
Deployment & Security
- Encrypted model deployment and secure boot
- OTA updates without production downtime
- Sub-millisecond inference for zero-latency decisions
Controls & Line Integration
PLC, reject gates, and production line connectivity
Our systems don't just detect — they actuate. We integrate inspection results directly into your production line controls: PLC outputs, reject mechanisms, line speed synchronization, and pass/fail signaling.
Integration Points
- PLC communication (Modbus, EtherNet/IP, PROFINET)
- Digital I/O for pass/fail reject signals
- Pneumatic and servo-driven reject gate control
- Encoder-based line speed synchronization
- Camera trigger and strobe synchronization
Commissioning
- On-site installation and line integration
- Production-speed validation and calibration
- Operator training and documentation
Production Analytics
Real-time dashboards, trending, and MES connectivity
Every inspection event is logged and visualized. Our analytics layer gives production managers real-time visibility into quality trends, defect rates, and system performance — with optional connectivity to your MES/SCADA.
Dashboard Features
- Real-time defect rate and trend visualization
- Shift, batch, and SKU-level reporting
- Image archive with defect classification labels
- Alert thresholds and notifications
Enterprise Integration
- MES / SCADA connectivity via OPC-UA or REST API
- Database export for quality engineering analysis
- Multi-line and multi-site consolidation
Mechanical Design & Fabrication
Custom enclosures, mounts, and structural assemblies
Every inspection system needs precision mechanical components — camera mounts, lighting brackets, enclosures, and conveyor frames. We design, fabricate, and assemble custom mechanical solutions that integrate seamlessly with your production line.
Design Capabilities
- 3D CAD modeling (SolidWorks, Fusion 360) for custom fixtures and enclosures
- FEA analysis for vibration, thermal, and structural integrity
- GD&T-driven tolerancing for precision camera and optics mounting
- DFM optimization for sheet metal, CNC, and 3D-printed components
- IP65/IP67 enclosure design for washdown and harsh environments
Fabrication & Assembly
- Sheet metal fabrication — laser cutting, bending, welding, powder coating
- CNC machining for precision lens mounts and alignment fixtures
- 3D printing for rapid prototyping and low-volume custom parts
- Full mechanical assembly and integration with electrical systems
Material Handling Systems
Conveyors, feeders, diverters, and reject mechanisms
Inspection accuracy depends on consistent product presentation. We design and build purpose-built material handling systems — conveyors, feeders, singulators, and reject mechanisms — engineered specifically for vision inspection requirements.
Conveyor Systems
- Belt, modular, and vacuum conveyors for stable product positioning
- Variable speed drives synchronized with camera triggers and encoders
- Multi-lane sorting conveyors with grade-based diversion
- Accumulation and staging conveyors for batch inspection
Feeding & Reject Systems
- Vibratory bowl feeders for bulk part singulation and orientation
- Linear feeders and escapements for precise part spacing
- Pneumatic air-blast reject systems for high-speed ejection
- Servo-driven diverter gates for multi-grade sorting
- Gravity chutes and collection bins for rejected product
System Testing & Validation
FAT, SAT, and production-speed qualification
Before any system ships, it undergoes rigorous testing and validation. We run factory acceptance tests (FAT) at our facility, followed by site acceptance tests (SAT) on your production floor — ensuring the system meets performance specifications under real conditions.
Test Protocols
- Factory Acceptance Test (FAT) with customer-supplied samples
- Site Acceptance Test (SAT) at production speed and conditions
- Gage R&R studies for measurement repeatability and reproducibility
- Confusion matrix validation — precision, recall, and false positive rates
- Endurance testing — 24/7 continuous operation validation
Documentation & Compliance
- IQ/OQ/PQ documentation for regulated industries (pharma, medical)
- Calibration certificates and traceability records
- Operator training manuals and SOPs
- Ongoing support, model retraining, and system optimization
Ready to Discuss Your Inspection System?
Our engineers will evaluate your application and design a system tailored to your production requirements.