<h2 id="isPasted">Introduction – Redefining Automotive Manufacturing</h2><p>Additive manufacturing (AM) has evolved from a specialised prototyping tool into a vital production technology for the automotive sector. In Europe, Original Equipment Manufacturers (OEMs) and Tier-1 suppliers are increasingly integrating AM into tooling, maintenance, and small-series production, where it helps to reduce lead times and improve design flexibility. The focus is now on ensuring AM meets the strict reliability and quality standards required for high-volume manufacturing. Manufacturers are working to optimise production by integrating machines, materials, and data flows to drive efficiency and ensure regulatory compliance. This integration is key to enabling consistent, scalable production while maintaining flexibility and reducing costs [1] [2].</p><p>As the industry prepares for <a href="https://formnext.mesago.com/frankfurt/en.html" target="_blank">Formnext 2025 in Frankfurt</a>, attention will shift towards practical adoption strategies. OEMs will continue to refine their processes, qualify new materials, and enhance the connectivity of AM data within digital-manufacturing and compliance frameworks. This will be crucial for accelerating AM’s role in mainstream automotive production, reducing costs, and meeting the growing demand for sustainable manufacturing solutions.</p><h2>Why Additive Manufacturing Matters?</h2><p>External pressures and internal advantages shape the strategic relevance of AM.</p><h3>Supply-Chain Resilience</h3><p>On the operational side, distributed AM enables localised manufacturing of spares and replacement parts. Daimler Truck | Daimler Buses, working with 3D Systems, Oqton, and Wibu-Systems, has launched a decentralized spare-parts printing program that allows authorized partners to produce certified components locally, cutting logistics dependencies and reducing lead times by up to 75 percent [3].</p><h3>Regulatory and Sustainability Momentum</h3><p>At the policy level, the European Union’s Right-to-Repair Directive and the Ecodesign for Sustainable Products Regulation are advancing requirements for product traceability and compliance with the circular economy [4][5]. Because AM inherently captures design, material, and process data, it aligns naturally with these frameworks—making it both a performance enabler and a compliance-ready manufacturing method.</p><h3>Industrial and Design Benefits </h3><p>The internal incentives for adopting AM are equally strong. Additive processes accelerate prototyping and tooling, reducing design-to-production cycles from weeks to days. They enable complex geometries and lattice structures that lower weight while maintaining structural integrity. By eliminating tooling investment, AM enhances cost transparency for low-volume runs and streamlines design revisions. It also extends the service life of products, as legacy or low-demand parts can be produced on demand rather than stored [1][6]. </p><h2>Materials and Manufacturing Processes</h2><h3>Polymers</h3><p>Selective-laser-sintering (SLS) and Multi Jet Fusion (MJF) remain the most widely used AM methods for robust PA12 and PA12-GF parts. Tier-1 supplier Brose employs SLS for end-use components such as a 20,000-unit Bowden-release assembly, showing that controlled, mid-volume polymer AM can meet cost and reliability targets [7].</p><h3>Metals</h3><p>OEMs are consolidating capacity and exploring binder-jet productivity. Volkswagen has added a second Additive Industries MetalFAB system at Wolfsburg and continues its collaboration with HP on Metal Jet to increase throughput for qualified geometries [8].<br />Large-format &amp; repair. </p><p>Wire-Arc Additive Manufacturing (WAAM) and Directed-Energy Deposition (DED) are increasingly applied to heavy-duty tooling and repair [9]. Automated depowdering and finishing, frequently demonstrated at trade fairs, illustrate how AM cells are being industrialised rather than kept as R&amp;D islands [10]. </p><h2>Case Studies </h2><h3>BMW Group </h3><p>The Additive Manufacturing Campus near Munich has become the model for serial AM integration in Europe, producing more than 300,000 parts annually and serving as the network’s knowledge hub [11].</p><h3>Daimler Truck | Daimler Buses </h3><p>By partnering with 3D Systems and Oqton, Daimler is transforming spare-parts logistics into a distributed, certified manufacturing model—embedding AM directly within maintenance workflows [3].</p><h3>Renault Group </h3><p>At its Flins Refactory, Renault operates a 500 m² additive centre with around 18 polymer printers for tooling and spare parts. In 2022, the company installed an AM Solutions S1 post-processing unit to automate the depowdering and finishing of MJF PA12 parts, improving repeatability and reducing manual labor within its circular manufacturing “Re-Factory” program [12].</p><h3>Volkswagen Group </h3><p>Wolfsburg’s expansion of metal AM, including binder-jet and hybrid AM + CNC routes, targets industrial-scale productivity gains and cost transparency across production programmes [8].</p><h3>Mercedes-Benz Classic</h3><p>Operates a certified 3D-printing programme to produce genuine replacement parts to original specifications for heritage vehicles, proving that additive methods can meet OEM quality and documentation standards [13].</p><h1>Practical Roadmap for Adoption</h1><p>Start by focusing on parts with high downtime costs and low production volumes, such as jigs, fixtures, or obsolete service spares. Standardise on a small selection of materials (e.g., PA12 for polymers, AlSi10Mg for metals) to ensure consistency and reduce complexity.</p><p>Develop internal Design for Additive Manufacturing (DfAM) guidelines to optimise part geometry for AM, ensuring efficient use of materials and build time.</p><p>Traceability is crucial: capture all data from build files to inspection results, feeding it into your enterprise systems to meet Digital Product Passport (DPP) requirements. Automate post-processing steps, such as depowdering and finishing, to improve consistency, as seen at Renault’s Flins site. Lastly, pilot secure remote printing using encrypted files and machine authentication, a model already in use by companies like Daimler.</p><h1>Applications and Future Outlook </h1><p>AM’s automotive role is widening but remains application-driven. It is mature in prototyping and tooling, expanding in spare-parts production, and selectively applied to low-volume serial components. The convergence of regulatory demands and digital-factory readiness is expected to accelerate the adoption of digital spare-part warehousing and hybrid AM/CNC workflows. Analysts project Europe’s AM market to grow at a rate of roughly 20 percent CAGR through 2030 [14], with the automotive sector as a key driver.</p><h2>Conclusion – Join the Additive Transformation</h2><p>As automotive manufacturers plan for the 2026–2028 cycle, AM is transitioning from isolated innovation to a standard manufacturing capability. It supports sustainability, repairability, and supply-chain agility while satisfying Europe’s new data-traceability norms. <a href="https://formnext.mesago.com/frankfurt/en/expo-convention/visitor-information.html?utm_source=chatgpt.com" target="_blank">Formnext 2025</a> will showcase how automation, certification, and digital integration are redefining production. For engineering and operations teams, it offers a concentrated opportunity to benchmark solutions and align additive strategies with long-term manufacturing goals.</p><h2>References</h2><ol><li><p>Formnext, Additive Manufacturing for the automotive industry: basic principles, recommendations, application examples and forecasts (White Paper)</p></li><li><p>European Patent Office – Innovation trends in additive manufacturing Patents in 3D printing technologies.</p></li><li><p>3D Systems &amp; Daimler Truck | Daimler Buses, Press Release (23 Jan 2025).</p></li><li><p>EUR-Lex, Directive (EU) 2024/1799 on common rules promoting the repair of goods, 2024</p></li><li><p>European Commission, Ecodesign for Sustainable Products Regulation (ESPR) overview, 2024</p></li><li><p>Hamza, A., Bousnina, K., Dridi, I., &amp; Ben Yahia, N. (2025). Revolutionizing automotive design: The impact of additive manufacturing. Vehicles,</p></li><li><p>Formlabs. (2024, November 7). How Brose leverages SLA and SLS technology to bolster automotive production.</p></li><li><p>Additive Industries. (2023, June 26). Volkswagen Group expands additive manufacturing capabilities with Additive Industries’ MetalFAB system.</p></li><li><p>RAMLAB. (n.d.). WAAM 101: An introduction to Wire Arc Additive Manufacturing.</p></li><li><p>VoxelMatters. The increasing automation of metal AM post-processing</p></li><li><p> BMW Group, 3D printing in BMW production, 2024.</p></li><li><p>Machine Insider.. Renault Flins invests in an S1 machine from AM-Solutions.</p></li><li><p>Mercedes-Benz AG. (n.d.). Next generation of genuine Mercedes-Benz replacement parts from the 3D printer</p></li><li><p>Global B2B Market Research Agency. Europe metal additive manufacturing market analysis</p></li></ol>

Additive Progressive Modeling Technology (Prototype of Car Engine - 3D Model)

Additive Manufacturing (AM) is transforming the European automotive industry; enhancing supply chain resilience, sustainability, and design freedom while driving innovation toward scalable, data-driven production.

Additive Manufacturing in the Automotive Industry: Driving the Future of Mobility

<p id="isPasted">In the high-stakes world of modern manufacturing, a single defect can have cascading consequences. A microscopic crack in a turbine blade, an improperly seated component in a medical device, or a dimensional error in an automotive part can lead to catastrophic failures, costly recalls, and irreparable brand damage. It is therefore imperative that manufacturers can deliver high-quality components in a cost and time-efficient manner. </p><p>Central to this is the concept of zero-defect manufacturing (ZDM), a strategy that manufacturers in demanding industries, such as automotive and aerospace, subscribe to ensure that parts are made to specification the first time. While the original concept of “Zero Defects”—popular in the mid-1960s—was related to preventing production mistakes through worker motivation, today zero-defect manufacturing is made possible using cutting-edge digital tools, like AI-powered predictive maintenance and visual inspection, which enhance manufacturing workflows and ensure that no time or money is wasted on production errors.</p><p>Achieving flawless production across the broader manufacturing industry relies on two critical pillars: the optimization of in-house manufacturing processes using AI tools and the strategic refinement of external supply chains via intelligent digital platforms. In this article, we’ll be illuminating how AI-driven solutions are transforming factory floors into self-correcting ecosystems and how innovative digital manufacturing networks like FACTUREE are unlocking zero-defect manufacturing in the supply chain using data-driven solutions, ultimately making ZDM a tangible reality for businesses of all sizes.  </p><h2>The Aim of Zero-Defect Manufacturing</h2><p>In its simplest terms, zero-defect manufacturing is a quality management strategy that aims to eliminate errors and defects from all stages of the production process, thereby enhancing efficiency in terms of both cost and time. If a zero-defect manufacturing strategy is effective, manufacturers will perform well in terms of the First Time Right (FTR) KPI.</p><p>While other quality management strategies have relied on quality control and inspection processes to weed out failed parts, zero-defect manufacturing puts a greater onus on earlier stages in the production workflow, aiming to prevent issues before any time and resources are spent on producing a failed component. To put it succinctly: zero-defect manufacturing eliminates rework, waste, and unpleasant surprises. </p><p>ZDM has been a particularly popular strategy in demanding industries like automotive and aerospace, which are bound by strict safety and compliance standards and have a significant interest in keeping production costs as streamlined as possible. In these industries and others, manufacturers have increasingly embraced digital production tools to underpin manufacturing steps and exert greater control over previously variable factors. As we’ll see in more detail, AI-driven tools are unlocking greater automation and stability across the production chain, providing real-time process monitoring, data-driven optimization, predictive maintenance, enhanced traceability, and overall greater efficiency.</p><h2>Pillar One: Tighter In-House Process Controls with AI</h2><p>For companies operating their own manufacturing facilities, artificial intelligence has become integral to achieving zero-defect manufacturing, with AI-driven technologies like machine learning and computer vision enabling manufacturers to exploit data from along the production chain to predict and prevent manufacturing failures, thus dramatically reducing (if not completely eliminating) waste and guaranteeing first-time-right parts. </p><p>AI is used in four key ways by manufacturers, taking a zero-defect approach in-house:</p><h3>Predictive Quality Control</h3><p>At its foundation, predictive quality control is about preventing defects rather than simply identifying them in the final stages of production. This works by using machine learning models that have been trained on process data (i.e., temperature, humidity levels, material properties, and machine settings) and can effectively identify patterns in this data that may lead to defects. For example, a machine learning tool could alert operators if a temperature range previously correlated with a defective component or batch is about to be reached, allowing for the production to be paused and recalibrated before defects occur. </p><h3>Automated Visual Inspection</h3><p>AI computer vision can reinforce predictive quality control by automating visual inspection processes, which were previously carried out manually and prone to human error. This has huge benefits in production workflows, as cameras equipped with computer vision can analyze parts in real time—and at various production stages—to identify defects or imperfections, like scratches, cracks and dimensional inaccuracies. This immediate identification can remove defective parts as they occur, thereby shortening the time and resources required to finish and inspect a faulty component. In sum, leveraging AI for visual inspection in the production chain accelerates inspection times, minimizes human error, and boosts overall inspection accuracy.</p><h3>Predictive Maintenance</h3><p>AI-driven predictive maintenance systems significantly contribute to the overall goal of zero-defect manufacturing. AI tools analyze machine data (gathered from sensors that measure temperature, vibration, gas, and humidity, among other things) to predict machine failures and alert operators to maintenance requirements. This proactive approach to maintenance can eliminate unplanned machine downtimes and ensure that when machines are running, they are consistently making flawless components. For example, predictive maintenance tools can detect when a CNC machine requires a tool change before the quality of machined parts is affected by the worn component.</p><h3>Root Cause Analysis</h3><p>Finally, AI-enabled root cause analysis is central to achieving long-term, sustainable zero-defect manufacturing. AI algorithms can analyze vast quantities of production data from both successful production runs and defective batches, and from this data can find patterns and inconsistencies that show precisely where issues are born. From there, manufacturers can rapidly implement measures to eliminate the root cause of the problem, thus reinforcing the production chain and increasing efficiency through continuous improvement.</p><h2>Pillar Two: Applying ZDM to the Supply Chain with FACTUREE</h2><p>A zero-defect approach doesn’t stop at the factory gate. No matter how refined internal processes may be, a production chain is only as strong as its weakest link. In an era where components are increasingly sourced through global networks, it is essential that each link in the supply chain adheres to the same zero-defect principles. </p><p>This is where the second pillar of ZDM begins: with the intelligent, AI-driven optimization of external procurement processes, where procurement is evolved from a logistical task to a core pillar of quality assurance. </p><p>With Germany-based FACTUREE, this vision becomes reality. The company’s platform takes a data-first approach, leveraging AI to apply the preventative principles of in-house ZDM to its vast manufacturing network of over 2,000 qualified manufacturers. The intelligent supplier matching platform eliminates uncertainty by embedding quality from the start and creates seamless quality assurance across the entire supply chain.</p><p>Here’s how FACTUREE’s AI delivers on the promise of zero-defect sourcing:</p><h3>Deep Technical Analysis</h3><p>From the start, FACTUREE’s AI performs an analysis of a customer's technical requirements. Using sophisticated algorithms to interpret CAD files that users upload to FACTUREE’s platform, the AI deconstructs the geometry into key manufacturability features like tolerances, complexity, and material. It matches these against a dataset of its manufacturing partners' proven capabilities. FACTUREE knows a supplier’s capabilities and matches parts based on proven experience, material, and quality history. This ensures a perfect technical fit, preventing defects that arise from a supplier being challenged beyond their demonstrated expertise.</p><h3>Data-Driven Supplier Scoring</h3><p>FACTUREE’s AI also employs a dynamic supplier scoring system that creates a "living profile" for every production partner. This profile is continuously updated with real-world performance data from every job they complete, tracking quality and reliability across all projects. It also integrates data on delivery records, standards compliance (ISO 9001, AS9100), and equipment calibration. This means the AI doesn't rely on a supplier's stated capabilities, but on their proven, documented performance, ensuring every project is awarded to a partner with a verifiable track record of excellence.</p><h3>Quality Assurance and Process Transparency </h3><p>The company’s intelligent supplier matching is reinforced by a system that brings transparency to the entire production process. FACTUREE coordinates the process and ensures that suppliers have proper documentation, such as material certificates. This allows FACTUREE’s engineers to monitor progress for their customers. This managed process culminates in a rigorous secondary inspection conducted by FACTUREE's quality team. This final check acts as the ultimate failsafe, verifying every dimension and requirement before the parts are ever shipped, guaranteeing a zero-defect outcome for the customer.  </p><h2>Conclusion</h2><p>Zero-defect manufacturing is all about maximizing resources while consistently delivering on quality. Digital tools and AI systems are playing a key role in achieving ZDM in-house through the optimisation of internal processes, as well as ensuring it across external supply chains through intelligent networks like FACTUREE’s. Ultimately, both pillars are vital to creating a cohesive, data-driven manufacturing ecosystem that delivers on ZDM. By embracing both pillars, companies can finally move beyond the reactive cycle of defect detection and build a proactive, preventative strategy that delivers on the ultimate promise of zero-defect manufacturing: perfect quality, every time.</p><p>Learn more about FACTUREE’s digital manufacturing network or get a quote for a production job <a href="https://www.facturee.de/en/inquiry/" target="_blank">here</a>. </p>

Zero-Defect Manufacturing: Industrial Bearings of Different Sizes

AI tools like predictive maintenance, automated visual inspection, and intelligent supplier matching are setting a new standard for zero-defect manufacturing across the supply chain.

Using AI-Driven Digital Tools to Unlock Zero-Defect Manufacturing

<h2 id="isPasted">Introduction</h2><p>The burgeoning landscape of energy storage, driven in part by the demand for electric vehicles (EVs) and portable electronics, places an unprecedented emphasis on battery quality and reliability. To ensure quality and improve product safety and yield, X-ray inspection has become a standard requirement in manufacturing processes. In this context, Microfocus X-ray (MFX) source technology has emerged as a pivotal tool in non-destructive battery inspection across various types of battery cells. These systems combine high-resolution performance with easy integration and continuous operation, making them especially suitable for inline inspection in large-scale battery production.<sup>[1]</sup>This article examines the application of MFX source technology in inspecting cylindrical, pouch, and prismatic battery cells, highlighting its technical advantages, integration capabilities, and the increasing need for such inspections in modern manufacturing environments.</p><h2>Adaptable Inspection Across Cylindrical, Pouch, and Prismatic Cells</h2><p>The diversity in battery cell designs means each presents unique manufacturing challenges and inherent vulnerabilities. Cylindrical cells, with their robust metal casings, are widely adopted but still susceptible to winding defects. Pouch cells, prized for their flexible and lightweight design, are inherently delicate, making internal integrity particularly critical<sup>&nbsp;[1]</sup>.</p><p>Prismatic cells, offering excellent space efficiency, require precise alignment of their layered components. MFX sources excel in their ability to inspect all these battery types non-destructively, delivering a consistent and reliable quality control solution across the entire spectrum of battery production. This versatility means a single platform can cater to diverse product lines, streamlining inspection processes and reducing the need for specialised equipment for each cell format.</p><h3>Unveiling Micro-Anomalies with Precision Spot Size</h3><p>A defining feature of MFX technology is its exceptionally small focal spot size, often less than 100 µm<sup>&nbsp;[1</sup>].<strong>&nbsp;</strong>This attribute is crucial for achieving high-resolution imaging, allowing for the detection of minute defects that could compromise battery performance or safety.&nbsp;</p><p>The ability to resolve fine details is critical when assessing parameters such as anode-cathode separation and electrode alignment. Accurate measurement of these aspects ensures optimal electrochemical performance and mitigates risks associated with short circuits or thermal runaway.&nbsp;</p><p>In addition, high-resolution imaging enables the detection of microscopic foreign particles, potential initiation points for dendrite growth and internal shorts, as well as the verification of proper cell positioning within battery modules, which is vital for mechanical stability, thermal regulation, and electrical connectivity. MFX technology provides the precision necessary to carry out all these inspections reliably, supporting both safety and longevity in battery design.</p><h3>Simplified System Integration with True Mono-Block Design</h3><p>Beyond its exceptional imaging capabilities, MFX technology distinguishes itself with a true mono-block design. The mono-block design of MFX sources simplifies integration into existing production lines. This compact configuration minimises the need for extensive system modifications, enabling straightforward installation and maintenance. Moreover, the sealed nature of these units minimises the risk of contamination and enhances operational safety<sup>&nbsp;[2]</sup>.</p><h3>Versatile Imaging Capabilities</h3><p>MFX technology offers a versatile suite of imaging modalities for both 2D and 3D analysis. Each is engineered to address specific inspection requirements within battery manufacturing. This adaptability ensures that manufacturers can tailor their inspection approach to meet the complexity, scale, and precision required for each stage of production. 2D linear imaging is ideal for high-speed, continuous scanning on production lines, making it well-suited for detecting large-scale anomalies or inconsistencies across the length of battery cells, particularly during initial quality screening. A conceptual example of in-line cylindrical LiB is shown in Figure 1.&nbsp;</p><p>For more targeted internal assessments, laminography provides detailed, layer-by-layer visualisation, allowing engineers to uncover defects such as voids, delaminations, or misalignments within stacked electrode layers that may be concealed in traditional 2D projections. At the highest level of detail, 3D imaging enables comprehensive volumetric reconstruction of the battery’s internal architecture. This is crucial for complex defect analysis and advanced R&amp;D, as it reveals subtle structural inconsistencies such as uneven winding in cylindrical cells or multi-layer delamination in pouch designs.&nbsp;</p><p>Support for all three modalities — linear, laminographic, and 3D —allows MFX systems to empower manufacturers in selecting the most effective imaging technique for each application, ensuring maximum inspection accuracy while maintaining production efficiency. High-resolution X-ray imaging of lithium-ion batteries is made possible by Hamamatsu’s MFX sources paired with advanced detectors, which provide clear visualization of internal structures across various cell formats. As shown in Figure 2 , these systems successfully reveal defects such as gaps between anode and cathode layers, layer misalignment, and foreign particle contamination as small as 15 µm in anode/cathode sheets. This level of detail enables manufacturers to detect potential failure points early in the production process, ensuring higher yields, improved safety, and extended battery life<sup>&nbsp;[2,3,4]</sup>.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 833px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1752058609693-Ham_MFX_app_web.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false" aria-label="To enrich screen reader interactions, please activate Accessibility in Grammarly extension settings">Figure 2: Representative X-ray inspection images of lithium-ion batteries acquired using Hamamatsu MFX sources and detectors.</span></span></span></p><h2>The Role of Detectors in High-Precision MFX Imaging</h2><p>While MFX sources provide the high-resolution X-ray beam, the performance of the entire inspection system critically depends on the detector. For high-speed 2D inspection tasks, Hamamatsu’s time-delayed integration (TDI) cameras are widely used for their ability to capture fine structural changes in real time, thanks to their 48 µm pixel size and capability to acquire distortion-free images of moving objects.</p><p>For 3D volumetric imaging, especially cone-beam CT applications, the newly developed Flat Panel Sensor C16401SK-51 provides high spatial resolution, fast readout, and is designed specifically for advanced Li-ion battery inspection. This detector enables precise reconstruction of internal battery architecture, supporting defect analysis during both R&amp;D and production<sup>&nbsp;[5]</sup>.</p><h3>Proven Track Record and Growing Adoption</h3><p>MFX technology has established a substantial installed base across a wide range of industries, reflecting its proven reliability, accuracy, and adaptability in demanding inspection environments. In battery manufacturing specifically, its deployment has grown steadily as manufacturers seek robust, non-destructive solutions capable of meeting the high standards of precision required for modern energy storage systems. Companies have successfully integrated their MFX systems into high-throughput production lines, demonstrating the technology’s maturity, ease of integration, and consistent performance under real-world manufacturing conditions.&nbsp;</p><p>These case studies highlight not only the technical advantages of MFX systems but also their long-term operational stability and minimal maintenance demands. As the battery industry continues to evolve, driven by electric mobility, grid-scale storage, and portable electronics, the adoption of MFX inspection solutions is expected to accelerate further, fuelled by the growing emphasis on quality assurance, yield optimisation, and regulatory compliance across the global supply chain<sup>&nbsp;[1]</sup>.</p><h3>Localization Drives Inspection Innovation in EU Gigafactories</h3><p>The current global geopolitical climate and supply chain vulnerabilities are accelerating the trend towards localised battery production. However, while the trend toward localized battery production remains a strategic priority, several Gigafactory projects across the EU have encountered delays, restructuring, or shifts in investment focus due to evolving market and financial conditions. Despite these challenges, the underlying need for flexible, high-performance inspection technologies like MFX is growing. As production moves closer to assembly facilities, local manufacturers must assume full responsibility for quality control, from raw materials to finished cells, without relying on distant quality assurance checkpoints.&nbsp;</p><p>Robust internal inspection becomes essential to mitigate risks within the supply chain and prevent costly disruptions. Additionally, compliance with stringent regional regulations, particularly in the EU, requires thorough and traceable inspection processes to ensure that safety and environmental standards are met. Localised production also fosters innovation, with more customised chemistries and cell designs emerging from regional R&amp;D efforts. MFX technology, with its flexible imaging capabilities, supports this by enabling precise evaluation of new structures and materials. Finally, real-time inspection within domestic facilities shortens feedback loops, allowing for immediate corrective action and continuous optimisation of production processes.</p><h2>Industry Spotlight: Hamamatsu’s Precision Imaging for Battery Inspection</h2><p>Among the leading innovators in MFX technology, Hamamatsu Photonics, backed by decades of photonics expertise, has distinguished itself with microfocus X-ray sources engineered for high-precision battery inspection. Their MFX sources enable ultra-high-resolution imaging of internal battery structures down to 0.25&nbsp;µm resolution.</p><p>This level of detail is crucial not just for detecting standard manufacturing defects but for identifying microscopic anomalies, such as filamentous dendrite precursors or misaligned separator layers, that can be easily overlooked with conventional imaging tools.</p><p>Designed with manufacturability in mind, Hamamatsu’s sealed-type MFX sources offer a compact, mono-block architecture that simplifies integration into existing production lines. The sealed design also reduces potential contamination risks and minimizes the need for frequent servicing, ensuring high system uptime — a key requirement in continuous, high-throughput environments like Gigafactories.</p><p>In real-world deployments, Hamamatsu’s systems have been praised for their consistency, reliability, X-ray emission stability and minimal maintenance overhead, enabling manufacturers to conduct critical quality inspections without slowing down production. Their proven track record across multiple industries further validates the robustness of their MFX solutions as manufacturers scale up and diversify battery designs.</p><h2 id="isPasted">Conclusion: MFX as a Cornerstone of Battery Quality Assurance</h2><p>As the battery industry accelerates toward higher energy densities, faster production cycles, and localized Gigafactory ecosystems, quality assurance can no longer be an afterthought; it must be embedded into the core of manufacturing. Microfocus X-ray (MFX) sources technology offers a uniquely powerful solution, combining high-resolution, non-destructive imaging with flexible integration and modality options tailored to every cell architecture.</p><p>With industry leaders like Hamamatsu pushing the boundaries of precision and reliability, offering ultra-fine focal spot sizes and systems optimized for high-throughput environments. MFX inspection is quickly becoming a benchmark for safe, efficient, and scalable battery production. From early-stage R&amp;D to mass production lines, MFX systems enable manufacturers to detect the smallest internal defects, reduce waste, and continuously refine their processes.</p><p>In an era where even the tiniest flaw can compromise the safety of a vehicle or a device, internal battery integrity is no longer optional; it’s mission-critical. MFX sources technology powers a brighter, safer electrified future.</p><p>For further technical details, the <a href="https://www.hamamatsu.com/jp/en/news/products-and-technologies/2025.html">2025 Hamamatsu MFX X-ray Sources Catalog</a> offers a complete overview of available sealed and open-type systems.</p><h3>References:</h3><ol start="1" type="1"><li>Hamamatsu Photonics. (n.d.). X-ray Imaging Questions &amp; Answers [Online]. Available: <a href="https://hub.hamamatsu.com/us/en/ask-an-engineer/imaging/x-ray-imaging-questions-and-answers.html">https://hub.hamamatsu.com/us/en/ask-an-engineer/imaging/x-ray-imaging-questions-and-answers.html</a></li></ol><ol start="2" type="1"><li>Hamamatsu Photonics. (2025). <em>Microfocus X-ray Sources Catalog</em>.&nbsp;</li><li>Hamamatsu Photonics K.K., <em>Lithium-ion Battery Inspection</em>. [Online]. Available: <a href="https://www.hamamatsu.com/us/en/applications/industrial-x-ray-ndt-inspection/lithium-ion-battery-inspection.html">https://www.hamamatsu.com/us/en/applications/industrial-x-ray-ndt-inspection/lithium-ion-battery-inspection.html</a></li><li>S. Kumari, “How advanced X‑ray and inspection technologies are powering safer, smarter Gigafactory batteries,” The Battery Magazine, May 20, 2025. [Online]. Available: <a href="https://www.thebatterymagazine.com/how-advanced-x-ray-and-inspection-technologies-are-powering-safer-smarter-gigafactory-batteries/">https://www.thebatterymagazine.com/how-advanced-x-ray-and-inspection-technologies-are-powering-safer-smarter-gigafactory-batteries/</a></li><li>Hamamatsu Photonics, “C16401SK-51: X-ray flat panel sensor,” Hamamatsu Photonics, [Online]. Available: &nbsp;<a href="https://www.hamamatsu.com/jp/en/product/optical-sensors/image-sensor/x-ray-flat-panel-sensor/C16401SK-51.html">https://www.hamamatsu.com/jp/en/product/optical-sensors/image-sensor/x-ray-flat-panel-sensor/C16401SK-51.html</a></li></ol><p><br></p>

This article examines the application of MFX source technology in inspecting cylindrical, pouch, and prismatic battery cells, highlighting its technical advantages, integration capabilities, and the increasing need for such inspections in modern manufacturing environments.

Microfocus X-Ray Sources for Li-ion Batteries: High-Resolution Inspection from Cylindrical to Prismatic Cells

<p dir="ltr" id="isPasted">Additive manufacturing has changed the way engineers design and produce high-performance components<sup>[1]</sup>. This is further improved by reinforcing filament materials, such as carbon fiber. Its ability to enhance a base material's strength and thermal stability has made it a go-to additive in high-performance filament formulations.<sup>[2]</sup></p><p dir="ltr">However, it's not just about the reinforcement material. The geometry of the carbon fiber reinforcement, such as fiber length, aspect ratio, and distribution, also plays a critical role in defining the final part's properties.<sup>[3] </sup>These geometric variables determine how the fibers interact with the polymer matrix, influence flow behavior during printing, and affect the strength of the part post-processing.</p><p dir="ltr">Leading this space is 3DXTECH, an advanced materials manufacturer based in Michigan. With a broad portfolio of carbon fiber-reinforced materials, 3DXTECH offers high-performance filaments, including PEEK, PEKK, and Ultem, alongside custom formulations tailored to specific project needs.</p><h2 dir="ltr">Understanding the Types of Carbon Fiber Reinforcement</h2><p dir="ltr">To fully grasp how reinforcement geometry affects part performance, we first need to understand the primary types of carbon fiber fillers used in additive manufacturing: chopped and milled carbon fibers. Each has distinct characteristics, manufacturing processes, and applications.</p><h2 dir="ltr">Chopped Carbon Fiber</h2><h3 dir="ltr">Definition and Characteristics</h3><p dir="ltr">Chopped carbon fiber consists of continuous carbon filaments cut into short lengths, typically ranging from a few millimeters to a few centimeters. These fibers are then integrated into thermoplastics like PLA, ABS, or nylon to enhance mechanical properties. Chopped carbon fiber offers superior mechanical strength even at high temperatures, making it a go-to choice for high-performance applications. Its low coefficient of linear thermal expansion ensures dimensional stability under thermal stress. Lastly, its low moisture absorption makes it suitable for harsh environments.</p><h3 dir="ltr">Manufacturing Process</h3><p dir="ltr">The process starts with polyacrylonitrile (PAN) or pitch, which are widely used for making carbon fibers. In the next step, known as carbonization, the material is exposed to high temperatures in an oxygen-free environment. Once carbonized, the fibers are cut to precise lengths using specialized rotary cutters.<sup>[4]</sup> These short fibers are then compounded with a thermoplastic resin, such as polycarbonate or nylon, to create a filament suitable for fused deposition modeling (FDM) or fused filament fabrication (FFF) 3D printing. The compounding process ensures uniform fiber distribution, which is critical for consistent mechanical performance.</p><h3 dir="ltr">Applications</h3><p dir="ltr">Thanks to its high strength-to-weight ratio, chopped carbon fiber is widely used in aerospace for brackets and structural components, and in automotive for lightweight parts. Its ability to withstand high temperatures and chemical exposure makes it ideal for demanding environments like oil and gas or defense applications.</p><h2 dir="ltr">Milled Carbon Fiber</h2><h3 dir="ltr">Definition and Characteristics</h3><p dir="ltr">Milled carbon fiber consists of finely ground carbon particles, typically less than 1 mm in length. Unlike chopped fibers, milled fibers resemble a powder, offering unique advantages in dimensional stability and wear resistance. They also exhibit excellent resistance to a wide range of chemicals, including automotive fluids and fully halogenated hydrocarbons, making them suitable for precision components.</p><h3 dir="ltr">Manufacturing Process</h3><p dir="ltr">Milled carbon fiber is produced by grinding continuous carbon fibers using hammer or ball milling processes.<sup>[5]</sup> The resulting fine particles are then blended with a resin matrix to create a composite filament. This process allows for a higher degree of uniformity in the filament, which translates to improved printability and surface finish.</p><h3 dir="ltr">Applications</h3><p dir="ltr">Milled carbon fiber is commonly used in applications requiring high precision and smooth surface finishes, such as aerospace components and electronics enclosures. Its ability to maintain dimensional accuracy makes it a preferred choice for parts where tight tolerances are critical.</p><h2 dir="ltr">Comparison of Chopped vs. Milled Carbon Fiber</h2><p dir="ltr">The differences between chopped and milled carbon fibers significantly impact the performance of 3D printed parts. Below is a detailed comparison of their key properties to help engineers evaluate which reinforcement type suits their project needs.</p><div dir="ltr" align="left" id="isPasted"><table><tbody><tr><td><p dir="ltr">Property</p></td><td><p dir="ltr">Chopped Carbon Fiber</p></td><td><p dir="ltr">Milled Carbon Fiber</p></td></tr><tr><td><p dir="ltr">Tensile Strength</p></td><td><p dir="ltr">High</p></td><td><p dir="ltr">Moderate</p></td></tr><tr><td><p dir="ltr">Dimensional Accuracy</p></td><td><p dir="ltr">Moderate</p></td><td><p dir="ltr">High</p></td></tr><tr><td><p dir="ltr">Flexural Strength</p></td><td><p dir="ltr">High</p></td><td><p dir="ltr">Moderate</p></td></tr><tr><td><p dir="ltr">Surface Finish</p></td><td><p dir="ltr">Rough</p></td><td><p dir="ltr">Smooth</p></td></tr><tr><td><p dir="ltr">Aspect ratio</p></td><td><p dir="ltr">High</p></td><td><p dir="ltr">Low</p></td></tr><tr><td><p dir="ltr">Printability</p></td><td><p dir="ltr">Moderate</p></td><td><p dir="ltr">Excellent</p></td></tr><tr><td><p dir="ltr">Shape</p></td><td><p dir="ltr">Rod like</p></td><td><p dir="ltr">Fine powder</p></td></tr><tr><td><p dir="ltr">Thermal Conductivity</p></td><td><p dir="ltr">High</p></td><td><p dir="ltr">Moderate</p></td></tr><tr><td><p dir="ltr">Moisture Absorption</p></td><td><p dir="ltr">Low&nbsp;</p></td><td><p dir="ltr">Very Low</p></td></tr></tbody></table></div><p dir="ltr" id="isPasted">If you're printing a bracket or a structural load-carrying part where maximum stiffness and high-temperature strength are key, chopped carbon fiber is a better option. If you're designing an electronics housing or tooling insert where tight tolerances, excellent surface finish, and dimensional reliability are essential, milled carbon fiber is the superior choice.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 833px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1752054575852-chopped.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">A simple representation of chopped vs. milled carbon fiber. Image source: m-chemical.co.jp</span></span></span></p><h2 dir="ltr" id="isPasted">Comparison: 3DXMAX PC vs CarbonX PC+CF</h2><p>To show how reinforcement geometry affects material performance, we are going to compare two polycarbonate-based filaments from 3DXTECH: 3DXMAX PC and CarbonX PC+CF. While both share the same base polymer, the addition of carbon fiber in CarbonX PC+CF significantly changes how the material performs.</p><h3>3DXMAX PC</h3><p dir="ltr"><a href="https://www.3dxtech.com/products/3dxmax-r-pc">3DXMAX PC</a> is a high-performance polycarbonate filament made using Lexan resin from SABIC.<sup>[6]</sup> Designed for high-heat applications, it delivers outstanding mechanical strength, thermal resistance, and a clean surface finish for detailed, high-quality prints. This filament is compatible with FDM and FFF 3D printers equipped with a heated bed and heated build chamber. It prints reliably within an extruder temperature range of 280 to 310°C. It maintains excellent thermal stability owing to its high glass transition temperature of 147°C. Its amorphous molecular structure results in low, near-isotropic shrinkage when printed in a minimum 90°C chamber, which helps ensure dimensional accuracy when printing complex geometries. It is also known for impressive ductility, high impact resistance, and a virtually odorless printing process.</p><h3 dir="ltr">CarbonX PC+CF</h3><p dir="ltr"><a href="https://www.3dxtech.com/products/carbonx-pc-cf-1">CarbonX PC+CF</a> is a high-performance 3D printing filament made from carbon fiber reinforced polycarbonate. The addition of chopped carbon fiber boosts stiffness, dimensional stability, and strength. Its amorphous structure minimizes shrinkage and ensures near-isotropic mechanical properties, even in geometrically complex parts. CarbonX PC+CF prints within a wide temperature window of 280 to 310°C and requires a heated bed for optimal adhesion, as well as a heated build chamber. With a glass transition temperature of 127°C, this material offers some of the highest thermal performance available in 3D printing. A hardened steel nozzle with a minimum diameter of 0.4 mm is recommended to handle the abrasive carbon fiber content. Despite its industrial-grade performance, the material emits very little odor during printing, making it well-suited for professional environments focused on quality and reliability.</p><p>The following comparison between 3DXMAX PC and CarbonX PC+CF highlights the impact of carbon fiber reinforcement at a glance:</p><div dir="ltr" align="left" id="isPasted"><table><tbody><tr><td><p dir="ltr">Property</p></td><td><p dir="ltr">3DXMAX PC</p></td><td><p dir="ltr">&nbsp;CarbonX PC+CF</p></td></tr><tr><td><p dir="ltr">Density (g/cc)</p></td><td><p dir="ltr">1.2</p></td><td><p dir="ltr">1.36</p></td></tr><tr><td><p dir="ltr">Tensile Strength (MPa)</p></td><td><p dir="ltr">62</p></td><td><p dir="ltr">73</p></td></tr><tr><td><p dir="ltr">Tensile Modulus (MPa)</p></td><td><p dir="ltr">2410</p></td><td><p dir="ltr">6980</p></td></tr><tr><td><p dir="ltr">Tensile Elongation (%)</p></td><td><p dir="ltr">7</p></td><td><p dir="ltr">2.1</p></td></tr><tr><td><p dir="ltr">Flexural Strength (MPa)</p></td><td><p dir="ltr">78</p></td><td><p dir="ltr">85</p></td></tr><tr><td><p dir="ltr">Flexural Modulus (MPa)</p></td><td><p dir="ltr">2200</p></td><td><p dir="ltr">6540</p></td></tr><tr><td><p dir="ltr">Glass Transition Temp (Cel)</p></td><td><p dir="ltr">147</p></td><td><p dir="ltr">127</p></td></tr><tr><td><p dir="ltr">Deflection Temp (Cel)</p></td><td><p dir="ltr">135</p></td><td><p dir="ltr">119</p></td></tr><tr><td><p dir="ltr">Surface Resistance (Ohm/sq)</p></td><td><p dir="ltr">&gt; 10^13</p></td><td><p dir="ltr">10^9</p></td></tr><tr><td><br></td><td><br></td><td><br></td></tr></tbody></table></div><p><span class="fr-img-caption fr-fic fr-dib" style="width: 833px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1752054651743-gr+1.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false"></span></span></span></p><p dir="ltr" id="isPasted">Graphical representation of PC vs PC+CF performance.</p><p><br></p><h2 dir="ltr" id="isPasted">Comparison: MAX-G PETG vs CarbonX PETG+CF</h2><p dir="ltr">PETG is another popular base material known for its toughness, ease of printing, and chemical resistance. To further establish how carbon fiber reinforcement enhances performance, let’s pit two PETG-based filaments, MAX-G PETG and CarbonX PETG+CF, against each other.</p><h3 dir="ltr">MAX-G PETG</h3><p dir="ltr"><a href="https://www.3dxtech.com/products/max-g-petg-1">MAX-G PETG</a> is a durable material with excellent strength and flexibility. Made from FDA-approved base resin, it offers superior chemical resistance compared to PLA and ABS. This material stands out for its low moisture absorption, which is nearly three times lower than ABS. It has a wide processing range of 230 to 260°C. The amorphous structure ensures low, near-isotropic shrinkage, helping maintain dimensional accuracy throughout complex prints.</p><p dir="ltr">MAX-G PETG resists harsh chemicals such as isopropyl alcohol and produces very little odor during printing. It's a go-to solution for engineers who need a balanced combination of strength, durability, and printability.</p><h3 dir="ltr">CarbonX PETG+CF</h3><p dir="ltr"><a href="https://www.3dxtech.com/products/carbonx-petg-cf-1">CarbonX PETG+CF</a> is a carbon fiber reinforced PETG filament for enhanced strength, stiffness, and thermal performance. Reinforced with engineering-grade carbon, this formulation delivers superior mechanical properties and an excellent surface finish. It features an amorphous structure that minimizes shrinkage and offers near-isotropic behavior. It absorbs about three times less moisture than ABS and emits very little odor during printing.</p><p>The material has a wide processing window of 230 to 270°C. It requires a hardened steel nozzle with a minimum diameter of 0.4 mm.&nbsp;</p><p>CarbonX PETG+CF is ideal for structural components that need to withstand a moderate level of stress. It is particularly well suited to find a balance between lightweight construction, superior surface finish, and easy printability.</p><div dir="ltr" align="left" id="isPasted"><table><tbody><tr><td><p dir="ltr">Property</p></td><td><p dir="ltr">MAX-G PETG</p></td><td><p dir="ltr">CarbonX PETG+CF</p></td></tr><tr><td><p dir="ltr">Density (g/cc)</p></td><td><p dir="ltr">1.2</p></td><td><p dir="ltr">1.34</p></td></tr><tr><td><p dir="ltr">Tensile Strength (MPa)</p></td><td><p dir="ltr">45</p></td><td><p dir="ltr">56</p></td></tr><tr><td><p dir="ltr">Tensile Modulus (MPa)</p></td><td><p dir="ltr">1650</p></td><td><p dir="ltr">5230</p></td></tr><tr><td><p dir="ltr">Tensile Elongation (%)</p></td><td><p dir="ltr">24</p></td><td><p dir="ltr">3</p></td></tr><tr><td><p dir="ltr">Flexural Strength (MPa)</p></td><td><p dir="ltr">72</p></td><td><p dir="ltr">80</p></td></tr><tr><td><p dir="ltr">Flexural Modulus (MPa)</p></td><td><p dir="ltr">1600</p></td><td><p dir="ltr">5740</p></td></tr><tr><td><p dir="ltr">Glass Transition Temp (Cel)</p></td><td><p dir="ltr">80</p></td><td><p dir="ltr">80</p></td></tr><tr><td><p dir="ltr">Deflection Temp (Cel)</p></td><td><p dir="ltr">70</p></td><td><p dir="ltr">77</p></td></tr><tr><td><p dir="ltr">Surface Resistance (Ohm/sq)</p></td><td><p dir="ltr">&gt;10^13</p></td><td><p dir="ltr">&gt;10^9</p></td></tr></tbody></table></div><p><span class="fr-img-caption fr-fic fr-dib" style="width: 833px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1752054691195-gr+2.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false"></span></span></span></p><p dir="ltr" id="isPasted">Graphical representation of PC vs PC+CF performance.</p><p><br></p><h2 dir="ltr" id="isPasted">How 3DXTECH Helps Customers Choose the Right Filament</h2><p dir="ltr">Choosing the right filament for your application isn't always straightforward. With a wide range of base materials and reinforcement types on the market, zeroing in on the right one can be time-consuming. That’s where 3DXTECH sets itself apart. More than just a materials supplier, the company acts as your technical partner. 3DXTECH works closely with engineers to match reinforcement type and formulation to your performance requirements. Their technical support team evaluates several parameters before making recommendations:</p><p><strong>Application requirements:</strong> Load-bearing, environmental resistance, chemical exposure.</p><p><strong>Printer capabilities:</strong> Nozzle temperature, heated bed availability, and chamber conditions.</p><p><strong>Desired properties:</strong> Strength, stiffness, dimensional accuracy, or finish.</p><p>The company also provides custom formulations for customers with niche or complex needs. Whether you are designing a prototype for the aerospace sector or producing functional parts for robotics, 3DXTECH ensures the material aligns with performance expectations. In addition, since all 3DXTECH’s materials are manufactured in the United States, customers are protected from supply chain disruptions and the highly volatile tariff situation.<sup>[7]</sup></p><h2 dir="ltr">Conclusion</h2><p>For engineers pushing the limits of additive manufacturing, understanding reinforcement geometry is crucial. The shape, size, and distribution of carbon fibers influence how these materials behave under stress, heat, and during the printing process.</p><p>Chopped fibers offer high tensile and flexural strength, making them ideal for load-bearing parts that require performance under stress. Milled fibers, with their fine particle structure, offer excellent dimensional stability and printability, especially when tight tolerances and smooth finishes are important.</p><p>Carbon fiber reinforcement doesn’t just make materials stronger; it enhances thermoplastics so they can meet demanding specs for industrial use. In sectors such as aerospace, automotive, and robotics, CF-filled filaments unlock new design possibilities.</p><p>To get the most out of your next design, choose the reinforcement that matches your performance goals. Visit <a href="http://3dxtech.com">3DXTECH.com</a> to explore detailed material specs, request samples, or connect with a technical expert who can help you select the right filament for your application.</p><h2>References:</h2><p>&nbsp;1. https://www.sciencedirect.com/science/article/pii/S2666496825000226</p><p>2. https://ultimaker.com/learn/carbon-fiber-3d-printing-revolutionizing-additive-manufacturing/</p><p>3. https://www.sciencedirect.com/science/article/pii/S2666912922000277?</p><p>4. https://advancedcarbonscouncil.org/blogpost/2151389/507386/The-Process-Behind-Chopped-Carbon-Fiber</p><p>5. https://www.sciencedirect.com/science/article/abs/pii/S1359835X2200430</p><p>6. https://www.sabic.com/en/products/polymers/polycarbonate-pc/lexan-resin</p><p>7. https://www.3dxtech.com/blogs/featured/tariffs-drive-urgent-need-for-u-s-based-suppliers-2</p>

Explore how fiber length, shape, and distribution impact mechanical properties beyond just material choice

The Role of Reinforcement Geometry in Boosting 3D-Printed Part Performance

<p dir="ltr" id="isPasted"><em>Hexagon’s MAESTRO is setting a new benchmark in CMM technology with its fast, user-friendly and fully connected design to meet the real-time demands of aerospace &amp; defence manufacturer. From turbine blades to fuselage components, manufacturers are under pressure to maintain compliance with stringent standards, reduce costs, and respond rapidly to shifting demand.</em></p><p dir="ltr" id="isPasted">In advanced manufacturing environments, precision and responsiveness have become non-negotiable. The Hexagon&nbsp;<a href="https://hexagon.com/products/maestro">MAESTRO</a> Coordinate Measuring Machine (CMM) system, specifically designed for the smart factory era, is redefining quality inspection through speed, simplified operation, and Industrial Internet of Things (IIoT) enabled connectivity. MAESTRO integrates intelligence, automation, and adaptability with a focus on empowering aerospace &amp; defence manufacturers to keep up with escalating production demands and tighter quality requirements. This article explores MAESTRO’s game-changing features, tech innovations, and how it meets the demands of today’s advanced manufacturing.</p><h2 dir="ltr">Why a Digital-First CMM Is Crucial for Aerospace</h2><p dir="ltr">Aerospace manufacturers today need to deliver of backlogs and big order without compromising quality. This requires metrology solutions that can keep pace with rapid manufacturing speeds without becoming a bottleneck. Moreover, the Industry 4.0 principles demand that measurement systems provide smooth digital connectivity, real-time data access, and integration with broader smart factory ecosystems.&nbsp;</p><p dir="ltr">Conventional CMMs often suffer from complex programming requirements that necessitate highly specialized skills, which leads to slower setup and increased risk of human error. Moreover, traditional CMMs tend to operate as isolated units with limited connectivity, resulting in disconnected data silos that impede collaboration and timely decision-making across teams. This lack of integration also limits the ability to implement predictive maintenance or to fully utilize IIoT capabilities. Hexagon’s MAESTRO CMM platform is designed to address all these challenges head-on.&nbsp;</p><h2 dir="ltr">MAESTRO - A CMM Engineered for Advanced Aerospace Manufacturing</h2><p dir="ltr">MAESTRO features an all-digital design optimized for integration with IIoT ecosystems. Its networked architecture facilitates real-time data exchange, remote monitoring, and predictive maintenance. MAESTRO communicates measurement data and functions as a connected node within a broader manufacturing intelligence system. The system is designed for modularity and adaptability, which helps users to customize configurations to suit varying shop floor needs.&nbsp;</p><p dir="ltr"><iframe id="68667653dc03ce52d03a1caf" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/hexagon-cmm-maestro?iframe=true" frameborder="0" scrolling="no" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><br></p><h3 dir="ltr">Core Specifications</h3><p dir="ltr">MAESTRO is engineered to deliver industry-leading performance with core specifications that set it apart. The CMM achieves measurement speeds up to 1100 mm/s. Rapid probe changeovers further enhance throughput, reducing bottlenecks in production. With its high speed, MAESTRO also maintains high accuracy with a specification of ±1.2 μm plus L/300.&nbsp;</p><p dir="ltr">The system also employs advanced digital sensors that are automatically identified and calibrated upon installation. These sensors provide rich data streams that contribute to the machine’s self-awareness and enable predictive maintenance and real-time performance monitoring. Moreover, MAESTRO’s compact footprint allows it to fit into diverse manufacturing environments without compromising performance. This makes it suitable for integration into both existing production lines and new smart factory setups.</p><h3 dir="ltr">Intelligent Software Ecosystem that solves skilled labor gap</h3><p dir="ltr">MAESTRO’s intelligence is embedded in its software ecosystem, which enhances usability, accuracy, and connectivity. For instance, the digital twin mirrors the physical machine in a virtual environment, enabling offline programming, realistic simulation of measurement routines, and collision protection. PC-DMIS, the globally leading metrology software, integrates seamless with MAESTRO and provides tools for measurement programming, data analysis, and reporting. Similarly, Metrology Mentor is another intuitive software that guides users through measurement processes with assisted no-code workflows. Additional Nexus software, like Metrology Asset Manager, offer cloud-based connectivity and real-time monitoring of machine status, calibration history, and utilization metrics. It enables remote access and management of the CMM fleet, facilitating optimized scheduling, predictive maintenance, and enhanced overall equipment effectiveness (OEE).</p><h2 dir="ltr">The Four Pillars of the MAESTRO Revolution</h2><h3 dir="ltr">Speed</h3><p dir="ltr">MAESTRO delivers the fastest throughput in its class. This high speed is achieved through a combination of high acceleration and movement speed and synchronized wrist and machine axes, which move fluidly and in perfect harmony to accelerate both measurement and setup processes.&nbsp;</p><p dir="ltr">One of MAESTRO’s standout features is its probe changeover capability. Early benchmarks show up to 50% quicker exchange times than with traditional systems. This translates to less downtime between measurement routines and more time spent on productive work. Moreover, accelerated calibration routines, offering up to 85% time savings, ensure that even complex measurement jobs can keep pace with high-speed production environments.</p><h3 dir="ltr">Simplicity</h3><p dir="ltr">MAESTRO’s intuitive user interface and guided workflows, powered by Metrology Mentor software, make the most complex measurement tasks accessible to users of all skill levels. The system’s clear, modern display provides real-time status updates, operator instructions, and warnings, enabling quick, confident decision-making.</p><p dir="ltr">Every aspect of MAESTRO’s design works in concert to remove workflow complexity and reduce the risk of human error. This focus on simplicity ensures reliable, repeatable results and empowers teams to achieve more with less effort.</p><h3 dir="ltr">Connectivity</h3><p dir="ltr">MAESTRO is engineered as an IIoT device from the ground up. Its open platform enables smooth integration with existing industrial automation systems and software environments with no additional hardware required.</p><p dir="ltr">Real-time machine health and performance data are always accessible from anywhere via cloud-based dashboards. Centralized reporting and asset management tools, such as Metrology Reporting and Metrology Asset Manager, facilitate data-driven collaboration and decision-making across teams.&nbsp;</p><h3 dir="ltr">Future-Readiness</h3><p dir="ltr">MAESTRO’s modular architecture and robust technology roadmap ensure that the system can be upgraded in the field at any time, even years after initial deployment. This allows users to add new features or incorporate the latest technologies as their business grows or requirements change.</p><h2 dir="ltr">Next-Gen Technology Driving MAESTRO’s Capabilities</h2><p dir="ltr">MAESTRO is fast and intelligent. It combines a suite of next-generation technologies that simplify complex metrology tasks and ensure consistent measurement results with minimal manual intervention.&nbsp;</p><h3 dir="ltr">Digital Twin</h3><p dir="ltr">MAESTRO utilizes a digital twin, which allows users to program measurement routines offline with high confidence. This digital twin enables realistic simulations of part measurements, including probing paths and collision detection, ensuring validation of programs before actual execution. As a result, first-time-right measurement is achieved, reducing downtime and avoiding costly errors on the shop floor. The digital twin synchronizes instantly with the physical machine and its components, facilitating faster setup and smoother operation.</p><h3 dir="ltr">Smart Machine Eye</h3><p dir="ltr">MAESTRO is equipped with an embedded camera system known as the Smart Machine Eye. It provides remote visual access to the machine during operation and allows operators and support teams to monitor measurements in real-time from any location. It also supports troubleshooting by supplying video recordings in case of unplanned stops or issues.&nbsp;</p><h3 dir="ltr">Metrology Mentor</h3><p dir="ltr">The Metrology Mentor software is an intuitive, assisted workflow tool designed to simplify CMM programming and operation. It enables users of all skill levels to create measurement programs quickly and reliably without needing to write code. The software guides operators through industry-standard compliant GD&amp;T measurements. This approach reduces training requirements and operator dependency, which accelerates throughput and improves overall productivity in quality inspection processes.</p><h3 dir="ltr">Digital Racks &amp; Probes</h3><p dir="ltr">MAESTRO’s hardware ecosystem includes digital racks and probes that are automatically identified and initialized when mounted. This plug-and-play capability removes recalibration requirements when swapping sensors, enabling rapid changes between different measurement tasks or sensor types.&nbsp;</p><p dir="ltr">These advanced technologies position MAESTRO as a highly connected, efficient, and adaptable CMM solution that meets the demands of smart manufacturing environments.</p><h2 dir="ltr">Seamless Integration with the Smart Factory</h2><p dir="ltr">MAESTRO’s architecture is designed for seamless integration into digital manufacturing environments. For instance, MAESTRO provides real-time assessment of machine health, allowing manufacturers to monitor performance trends, schedule maintenance proactively, and maximize uptime. This integration ensures that metrology assets are not isolated components but vital nodes in a broader ecosystem of production intelligence.</p><p dir="ltr">The built-in Metrology Communication Interface (MCI) facilitates integration with automation systems, enabling MAESTRO to be incorporated into automated production lines. This interface supports near-line or in-line integration, allowing the CMM to communicate directly with robotic systems or other automated equipment. As a result, the measurement workflow can be automated easier than ever before.</p><p dir="ltr">MAESTRO’s open digital architecture supports connectivity with major industrial automation ecosystems. This interoperability ensures that quality data from the CMM is integrated into broader manufacturing workflows, facilitating data-driven decision-making and enhancing collaboration across departments. The digital platform also supports remote access and software updates, enabling continuous improvement of the smart factory’s metrology capabilities.</p><h2 dir="ltr">Performance that Grows with Your Business</h2><h3 dir="ltr">Upgrade Pathways: Accuracy+ and Throughput+</h3><p dir="ltr">One of MAESTRO’s standout features is its future-proof, modular architecture. Unlike traditional CMMs, MAESTRO allows users to enhance both accuracy and throughput at any stage of the machine’s lifecycle. The Accuracy+ and Throughput+ upgrade options allow users to boost the system’s precision or speed even years after installation. This flexibility allows users to respond to changing production demands or tighter quality standards without needing a complete hardware overhaul.</p><h3 dir="ltr">Support for Advanced Digital Sensors</h3><p dir="ltr">MAESTRO is designed to keep pace with the rapidly changing sensor technology. The platform natively supports the latest digital sensors, including a tactile scanning sensor or a laser scanner. These sensors enable a broader range of measurement applications and deliver higher data fidelity, allowing users to tackle more complex inspection tasks as the product portfolio diversifies.&nbsp;</p><h3 dir="ltr">The Platform of the Future: Continuous Innovation</h3><p dir="ltr">Hexagon’s commitment to innovation is embedded in the MAESTRO platform. As an all-digital, IIoT-enabled CMM, MAESTRO is built to accommodate future technological advances. The system’s open architecture and robust technology roadmap mean that new software features, automation integrations, and hardware enhancements can be adopted.&nbsp;</p><h3 dir="ltr">Sustainability by Design: EcoMode+</h3><p dir="ltr">MAESTRO incorporates features that help reduce the environmental footprint and promote sustainability. For instance, the EcoMode+ function intelligently manages compressed air and energy consumption, optimizing usage based on operational needs. MAESTRO minimizes resource consumption during idle periods and maximizes efficiency during operation, helping organizations achieve their sustainability goals and reduce utility costs.</p><h2 dir="ltr">Industry Applications: Proven Across Demanding Use Cases</h2><p dir="ltr">In the aerospace and defence sectors, MAESTRO delivers the high-speed and high-accuracy inspection of critical components like turbine blades, rotors, fuselage, tooling &amp; jigs and freeform components. Its ability to adapt to complex geometries and intricate surfaces ensures that all components meet performance specifications without slowing production. Moreover, MAESTRO's compatibility with optical sensors and its advanced design enables fast measurement of aerodynamic surfaces and rotating machinery parts with minimal repositioning, which reduces cycle time.</p><h2 dir="ltr">The MAESTRO Advantage Backed by Hexagon Expertise</h2><p dir="ltr">MAESTRO is the result of Hexagon’s decades-long leadership in metrology and digital manufacturing. It’s supported by Hexagon’s global MyCare service network, offering calibration, software maintenance, and on-demand technical support to ensure system longevity.</p><p dir="ltr">As a key component of Hexagon’s broader Manufacturing Intelligence portfolio, MAESTRO works in concert with other digital technologies to enable smarter design, production, and quality workflows in a connected, autonomous ecosystem.</p><h2 dir="ltr">Conclusion: A New Standard for Aerospace &amp; Defence in Digital CMMs</h2><p dir="ltr">Hexagon’s MAESTRO empowers aerospace manufacturers to enhance quality, reduce costs, and accelerate production by delivering speed, simplifying complex measurement tasks, enabling seamless digital connectivity, and offering a future-proof platform. As more and more industries embrace smart manufacturing, MAESTRO stands out as a critical enabler of this transformation, ensuring that quality inspection is not a bottleneck but a strategic advantage.</p><p dir="ltr">Explore how MAESTRO can help redefine your quality inspection processes by visiting the website: https://hxgn.biz/4j43jC4.</p><hr><h1 dir="ltr">References</h1><ol><li dir="ltr"><p dir="ltr">Hexagon. [Internet]. Available from:&nbsp;<a href="https://hexagon.com/">https://hexagon.com/</a></p></li><li dir="ltr"><p dir="ltr">Hexagon launches MAESTRO the next-generation Coordinate Measuring Machine. (2025) [Internet] Hexagon. Available from: <a href="https://hexagon.com/company/newsroom/press-releases/2025/hexagon-launches-maestro-the-next-generation-coordinate-measuring-machine">https://hexagon.com/company/newsroom/press-releases/2025/hexagon-launches-maestro-the-next-generation-coordinate-measuring-machine</a></p></li><li dir="ltr"><p dir="ltr">MAESTRO – The all-digital CMM system. [Internet] Hexagon. Available from: <a href="https://hexagon.com/products/maestro">https://hexagon.com/products/maestro</a></p></li></ol>

The new MAESTRO by Hexagon is setting a new benchmark in CMM technology with its fast, user-friendly and fully connected design to meet the real-time demands of aerospace & defence manufacturer.

The CMM System Remastering Aerospace & Defence Metrology with Speed, Simplicity, and Seamless Connectivity

<h2 id="isPasted">Introduction</h2><p>Artificial Intelligence is fundamentally transforming engineering. From streamlining design iterations to enhancing complex simulations, AI has evolved into a critical tool for product innovation. As industries face demands for faster development, higher performance, and increased sustainability, engineers are shifting toward intelligent, data-driven workflows.</p><p>At the forefront of this transformation is Altair, a global leader in computational science and artificial intelligence. With nearly four decades of expertise in simulation, high-performance computing and technology, Altair’s technologies empower engineers to design, simulate, and optimise faster and more effectively. Its platforms, such as SmartWorks, HyperWorks, and PhysicsAI, are used across the aerospace, automotive, electronics, and manufacturing industries to tackle complex engineering challenges with precision and agility.</p><p>This philosophy will take centre stage at ATCx AI for Engineers 2025, Altair’s global virtual event, which focuses on the practical impact of AI in engineering. Bringing together industry experts, engineers, and technologists, the event showcases how AI is being applied across various domains, disciplines, and the world.</p><p>One of the standout sessions features Ujwal Patnaik, Global Senior Director of Product Strategy at Altair, presenting his keynote <strong>“100 Use Cases Later: What AI Has Taught Us About Engineering”</strong>.</p><p>Rather than speculating about AI’s future potential, this session focuses on what AI is already doing—today. Ujwal draws from 100 real-world engineering implementations, spanning applications from crash simulation and battery health prediction to HVAC optimisation. The goal isn’t to walk through each use case, it’s to decode the bigger picture: What patterns emerge from successful AI workflows? What’s working across industries? Where is the real ROI—whether in time saved, waste eliminated, or quality gained?</p><p>As Ujwal puts it, “AI isn’t just a tool – it’s becoming a new way of engineering ”. And once you’ve seen what 100 real AI solutions look like, the natural question becomes: What’s stopping you from doing the 101st?</p><p><a href="https://events.altair.com/atcx-ai-for-engineers-2025/?utm_campaign=GLB-2025-06-ATCx-CVG-AI-for-Engineers&amp;utm_source=wevolver.com&amp;utm_medium=referral&amp;utm_content=atcx-ai-for-engineers-2025-wevolver-sponsored-landing-page" class="button-main-action">Register now.</a></p><h2>Engineering at the Speed of Intelligence</h2><p>Modern engineering isn’t just about performance it’s about making the smartest decisions in the shortest amount of time. As product requirements become increasingly complex and development cycles compress from years to months, engineers require tools that enable them to design, simulate, and optimise without delay. AI has emerged as a force multiplier. When paired with simulation, it unlocks the ability to explore more design alternatives, predict failures earlier, and reduce the need for repetitive physical testing. With Altair’s PhysicsAI, engineers can build surrogate models that replicate simulation results with a fraction of the computational effort—freeing up time and resources to innovate. Tasks like optimising aerodynamics or thermal dissipation now take hours instead of weeks. This speed doesn't come at the cost of accuracy, it’s built on it.</p><h2>What 100 Use Cases Reveal</h2><p>In his keynote, Ujwal Patnaik doesn’t just recount stories. He extracts patterns. Across the 100 use cases he analyses, four themes repeatedly emerge:</p><ol><li><p><strong>Start small, scale smart</strong><br />The most successful AI projects don’t aim to overhaul an entire product lifecycle on day one. They begin with high-impact, focused use cases, such as optimising component geometry, predicting mechanical fatigue, or accelerating computational fluid dynamics (CFD) studies. These small wins build momentum.</p></li><li><p><strong>Physics + AI is greater than either alone.</strong><br />Hybrid modelling is a recurring strategy that combines simulation data with machine learning models. By training AI on historical simulation results, teams create fast, reliable predictors that reduce solver time while preserving fidelity.</p></li><li><p><strong>The engineer remains central.</strong><br />Contrary to common fear, AI isn’t replacing engineers—it’s augmenting them. In the most effective deployments, engineers guide the models, define the constraints, and interpret results. AI handles the repetition, but humans retain control over the process.</p></li><li><p><strong>Data infrastructure matters</strong><br />Projects didn’t fail because the AI didn’t work—they struggled when data was siloed, messy, or incomplete. Clean, connected, and structured data pipelines made the difference between experimentation and scaled success.</p></li></ol><p>Ultimately, the session drives home one message: AI isn’t magic it’s a method. And like any method, it works best when it’s grounded in engineering judgment and enterprise readiness.</p><h2>Empowering Engineers, Not Replacing Them</h2><p>AI is only as powerful as the people who use it. That’s why Altair’s platforms are built with engineers, not data scientists, in mind. Altair SmartWorks is a low-code/no-code environment that allows engineers to integrate AI into their workflows without writing complex code. It democratises access to machine learning, making advanced analytics part of every engineer’s toolbox. Instead of relying on black-box tools, SmartWorks offers transparency and control. Engineers can train, validate, and deploy models themselves, keeping their domain knowledge at the centre of every prediction. This human-in-the-loop approach is a defining philosophy across Altair's offerings. AI supports creativity, accelerates exploration, and strengthens decision-making, but it’s the engineer who leads.</p><h2>Geometric Deep Learning: Engineering’s New Ally</h2><p>A compelling area of advancement is Geometric Deep Learning (GDL). Traditional machine learning is most effective with structured data, such as spreadsheets or image grids. However, engineering problems often involve complex 3D geometries such as meshes, surfaces, and point clouds, which GDL is specifically designed to handle. With GDL, engineers can build AI models that learn directly from CAD geometries and mesh data. Applications include stress prediction, crash analysis, fluid flow modelling, and structural optimisation, all executed significantly faster than traditional simulations. Altair’s work with PhysicsAI is pushing this frontier forward, allowing companies to simulate smarter and learn continuously from their geometry-driven design history.</p><h2>Three Sessions You Shouldn’t Miss</h2><p>Beyond keynotes, ATCx AI for Engineers 2025 features three in-depth technical sessions that offer actionable insights for different domains:</p><h3>Simulation-Driven Design</h3><p>This session explores how simulation has moved upstream in the development process. Engineers now use simulation not as a validation tool but as a real-time design driver. Presenters will share how meshless solvers, cloud-enabled simulation platforms, and integrated optimisation loops are unlocking rapid design exploration. Companies will demonstrate how they’re bringing new products to life with fewer physical prototypes and faster iterations.</p><h3>Where Physics Meets AI</h3><p>Here, Altair will showcase powerful hybrid approaches that combine classical physics solvers with data-driven AI models. The session features examples where AI has accelerated electromagnetic, thermal, and structural analysis without compromising reliability. Attendees will learn how to build and validate surrogate models, reduce simulation runtimes, and enhance overall design throughput. Emphasis is placed on keeping engineers informed while making workflows more scalable and intelligent.</p><h3>Accelerating AI Adoption for Smart Manufacturing</h3><p>Manufacturing is undergoing a major digital shift—and AI is at its core. This session explores how companies are utilising AI to implement predictive maintenance, defect detection, and real-time process optimisation. Altair’s experts will share frameworks for bridging the gap between IT and operations, overcoming challenges with legacy systems, and achieving early ROI. Live examples will show how manufacturers are embedding AI at the edge and on the shop floor to build truly adaptive systems.</p><p>To support a global audience, sessions will run in two time zones—APAC/EMEA and AMER/LATAM—and include live translations in eight languages: Spanish, French, Italian, Portuguese, German, Japanese, Chinese, and Korean.</p><h2>Why ATCx AI for Engineers 2025 Matters</h2><p>In today’s high-stakes engineering environment, access to cutting-edge tools isn’t enough. What matters is how quickly teams can turn those tools into solutions. That’s where events like ATCx become vital. They don’t just showcase technology. They offer a learning environment where strategy meets implementation.</p><p>The value of this event lies in its practical focus. Instead of abstract discussions, sessions are grounded in real business challenges—like reducing design cycle time, improving simulation coverage, and managing data across global teams. Whether you're a simulation analyst or a product innovation lead, you’ll come away with techniques and frameworks that apply immediately.</p><p>With a mix of case studies, product demonstrations, and strategic guidance, ATCx AI for Engineers 2025 provides participants with the knowledge and tools to start or scale their AI journey. The conversations will go beyond algorithms, to focus on the intersection of people, processes, and performance.</p><p>Whether you’re a hands-on design engineer, a digital transformation leader, or a systems architect, this event offers unmatched insight into the practical use of AI across engineering disciplines. The content isn’t theoretical, it’s built around real problems, proven results, and scalable solutions.</p><p>This is not a future vision, it’s happening now. And ATCx AI for Engineers 2025 is where you’ll see how.</p><p><a href="https://events.altair.com/atcx-ai-for-engineers-2025/?utm_campaign=GLB-2025-06-ATCx-CVG-AI-for-Engineers&amp;utm_source=wevolver.com&amp;utm_medium=referral&amp;utm_content=atcx-ai-for-engineers-2025-wevolver-sponsored-landing-page" class="button-main-action">Register now.</a></p><hr /><h3>References</h3><ul><li><p>Altair Executive Insights. (2024). What Is the Role of AI in Engineering?<br /><a href="https://altair.com/blog/executive-insights/2">https://altair.com/blog/executive-insights/2</a></p></li><li><p>Altair Executive Insights. (2024). Data Architecture: Warehouses, Lakes, and Fabric<br /><a href="https://altair.com/blog/executive-insights/data-architecture-approaches-data-warehouses-lakes-fabric">https://altair.com/blog/executive-insights/data-architecture-approaches-data-warehouses-lakes-fabric</a></p></li><li><p>Altair Executive Insights. (2024). Geometric Deep Learning, AI, and Altair PhysicsAI<br /><a href="https://altair.com/blog/executive-insights/geometric-deep-learning-ai-engineering-altair-physicsai">https://altair.com/blog/executive-insights/geometric-deep-learning-ai-engineering-altair-physicsai</a></p></li><li><p>Event Page: ATCx AI for Engineers 2025<a href="https://events.altair.com/atcx-ai-for-engineers-2025/"></a><a href="https://events.altair.com/atcx-ai-for-engineers-2025/"> https://events.altair.com/atcx-ai-for-engineers-2025/</a></p></li></ul>

ATCx AI for Engineers 2025, Altair's global virtual event, which focuses on the practical impact of AI in engineering. Bringing together industry experts, engineers, and technologists, the event showcases how AI is being applied across various domains, disciplines, and the world.

ATCx AI for Engineers 2025 Global Virtual Event

<p id="isPasted">Detecting defects on semiconductor wafers is extremely challenging due to their reflective surfaces, micro-scale defects, and the need for high precision. Manual parameter tuning and traditional rule-based approaches can be time-consuming and inconsistent, especially when scaling across varying product lines. Machine vision software is therefore playing an increasingly critical role in semiconductor manufacturing, by enabling automated, robust, and highly efficient optical inspection processes.</p><p>Join MVTec on June 5th for a step-by-step, demo-driven webinar and discover how advanced vision technologies are transforming wafer inspection and driving quality as well as throughput in semiconductor manufacturing.</p><p><br></p><p><a href="https://www.mvtec.com/application-areas/semiconductors/on-demand-webinar-how-to-maximize-the-yield-in-wafer-production" target="_blank" rel="noopener noreferrer" class="button-main-action">VIEW THE ON-DEMAND WEBINAR</a></p><h2><br></h2><p><strong id="isPasted">Discover a smarter way to detect wafer defects – no slides, just solutions.</strong></p><h3>What You’ll Learn</h3><ul><li><p>How Machine Vision can be used to&nbsp;detect defects on a wafer&nbsp;showing a&nbsp;live demo</p></li><li><p>Which&nbsp;technologies&nbsp;in&nbsp;MVTec HALCON&nbsp;can be used to&nbsp;maximize the yield</p></li><li><p>How MVTec can support you to start with an automated optical inspection</p></li></ul><h3><br></h3><p><br></p><p><br></p><table><tbody><tr><td><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQ2NzAzOTIyMjE3LW1zZV8yLmpwZWciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width:486px;" class="fr-fic fr-dib"></p></td><td><p><strong>Moderator</strong></p><p><a href="https://www.linkedin.com/in/markus-setzer-9113731b7/">Markus Setzer&nbsp;</a>has been a Marketing Specialist at MVTec for six years. In his role at MVTec, he talks a lot with customers and interested parties. Through trade fairs in particular, he has a deep insight into the industry's most pressing questions regarding machine vision in production. The demands of the market shape the structure of the webinar, which Markus Setzer will moderate.</p></td></tr><tr><td><p><strong>Application Engineer</strong></p><p><a href="https://www.linkedin.com/search/results/all/?fetchDeterministicClustersOnly=true&heroEntityKey=urn%3Ali%3Afsd_profile%3AACoAADfmAmIB6H7cwuWEOcdS5WcNGGUXKD81pmI&keywords=coco%20rogers&origin=RICH_QUERY_TYPEAHEAD_HISTORY&position=0&searchId=4e8844cd-9d7e-4dc1-b3b1-8a2f60079e25&sid=YTi&spellCorrectionEnabled=true">Coco Rogers</a> works as an Application Engineer in the Customer Service department and brings extensive expertise in defect detection. She has in-depth knowledge of the semiconductor industry and also develops demonstrators that showcase our software in action. During the webinar, Coco will give a live demonstration of how the optical inspection process of a wafer is performed using advanced machine vision technologies.</p></td><td><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQ2NzAzODg1MTAyLUNvY29fV2ViaW5hci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width:100%px;" class="fr-fic fr-dib"></p></td></tr></tbody></table><h2><br></h2><p><a href="https://www.mvtec.com/application-areas/semiconductors/on-demand-webinar-how-to-maximize-the-yield-in-wafer-production" target="_blank" rel="noopener noreferrer" id="isPasted" class="button-main-action">VIEW THE ON-DEMAND WEBINAR</a></p><h2 id="isPasted">About MVTec</h2><p>MVTec develops machine vision software used across a wide range of industrial applications, including semiconductor manufacturing. Its tools support tasks such as wafer alignment, inspection of dies and ball/wire bonds, defect classification, shape matching, precise measurement in 2D and 3D, as well as 3D robot guidance and identification. These capabilities contribute to improving production efficiency, enabling advanced manufacturing processes, and supporting applications where human-machine collaboration is required.</p>

Join MVTec to explore how advanced machine vision software is revolutionizing semiconductor wafer inspection with live demos, not slides—boosting precision, quality, and efficiency.

How to maximize the yield in wafer production webinar

<p>Automotive companies both large and small are adapting to new markets and new technologies. Harsh manufacturing environments, challenging targets, and operator safety require rugged and reliable solutions that reduce downtime due to inadvertent stoppages. As more sophisticated components find their way into vehicles automotive manufacturers will need to effectively modernize and optimize their production. </p><p>With robust sensors, lighting, condition monitoring, and safety, products, challenges related to quality inspection, assembly, finishing, and inventory tracking across the global supply chain are simplified. Every day, automotive and tyer manufacturers around the world rely on Banner to solve simple to complex automation challenges in the automotive marketplace. </p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742913703729-Auto_Assembly_Line_wCallouts+%281%29.jpg" style="width:100%px" class="fr-fic fr-dib" /></p><h3 id="isPasted"><strong>Image Key</strong></h3><ol><li>Measuring Sheet Metal Thickness</li><li>Light Tunnels for Paint Inspection</li><li>Safeguarding Areas on Assembly Lines</li><li>Predictive Maintenance and Condition Monitoring of Conveyors</li><li>Detecting Black Parts on Black Door Panel </li></ol><h2><br /></h2><h2><br /></h2><h2><br /></h2><h2><br /></h2><h2><strong>#1 Measuring Sheet Metal Thickness</strong></h2><p>In the automotive industry, sheet metal stamping is the process of cutting and shaping metal alloys into automotive frame brackets and other forms using a press tool. Metal stamping dyes are used to create high precision metal parts that are equal in shape and size. Automotive sheet metal stamping requires a specific thickness to ensure the parts are equal, and to ensure the dye is not damaged during the process to prevent down time and costly repairs. </p><p>As metal sheets move down the conveyor, laser displacement sensors measure the sheets on a very precise scale to ensure they are the correct thickness. Quality control is critical to reduce downtime and scrap and maintain high quality standards, so the finished product functions as intended for its useful life. Electrode thickness measurements are made after the coating and roll press processes. At these points, it’s critical to measure the electrode film thickness to determine if it was applied correctly, evenly, and whether any is missing. </p><p>The LM Series precision measurement sensor is a perfect solution because it is highly accurate and measures thickness at micron levels. The LM Series can also consistently look at dark targets on these levels and is capable of micrometer-level resolutions ranging from 2-4 microns, which gives it the ability to measure thickness of sheet metal quickly and accurately. Using a status display to show measurements of the electrode thickness helps operators quickly view measurements to determine if manufacturing requirements are on track. The SD50 Status Display informs operators about exactly what is going on so they can respond quickly and accurately.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742913725983-cq5dam.web.1280.1280.jpg" style="width:100%px" class="fr-fic fr-dib" /></p><h2><strong>Light Tunnels for Paint Inspection</strong></h2><p>To help prevent poor quality products from being distributed to customers, it is important to inspect vehicles before they leave the manufacturing plant. When inspecting metal or plastic surfaces in these conditions, imperfections such as fingerprints, dirt, or damaged areas can easily be overlooked. Materials that are shipped with these flaws may require additional repair or recall, which would then drive-up unwanted expenses and cause delays in production. Operators can experience eye strain when inspecting vehicles in paint tunnels. </p><p>Automotive factories need lights that help to reduce worker fatigue, eliminate defects, and allow proper inspection. Banner offers an assortment of LED products, such as the WLB92 and WLB72 task lights to help with this. Using LED lighting on factory floors offers many advantages. The focused beam and higher contrast enable workers to see contrast and make defects more visible to the human eye. Inspection using these lights reduces shadows, improves visibility, and gives workers the light they need to work efficiently and without making mistakes. This is especially important in the automotive industry where oil residue on metalized paint can make fisheye imperfections, which are small circular spots that appear on contaminated surfaces. </p><p>The black edges of the WLB72 shield workers from direct contact with the light when looking down the length of paint tunnels. The various rugged light fixtures offer high quality and low power illumination with the capability to be installed and rotated at different angles to better accommodate the needs of the operator. They have an estimated lifespan of over 50,000 hours and never require replacement bulbs or ballasts, providing years of maintenance-free illumination.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742913749763-banner+5.jpg" style="width:100%px" class="fr-fic fr-dib" /></p><h2><strong>#3 Safeguarding Areas on Assembly Lines</strong></h2><p>Large automotive assembly factories feature a wide range of machinery that have the potential to harm employees and proper safety measures are essential. As cars and other vehicles are assembled, they move further along a conveyor system, surrounded by automated heavy machinery and robotics. Personnel need to be protected from the vehicles and operating equipment to prevent injury. Areas along the assembly line can pose high levels of risk to operators feeding or removing parts and other personnel working in the manufacturing facility. Often times several safety systems are used simultaneously to prevent workers from entering hazardous areas. </p><p>The use of safety light curtains for safeguarding assembly lines has been one of the most common methods for protecting personnel. The heavy machinery generates high levels of shock, which increases the probability of physical impact to the guarding system and can also involve oil mist that degrades the light curtain performance. All of these challenges can result in unwanted interruptions in production to allow for safety system maintenance. A strong safety light curtain solution that can withstand the hostile environment in the press room is necessary for successful production. </p><p>The S4B Series Safety Light Curtains are a well-established solution for automotive assembly lines, with the ability to cascade or connect multiple segments together. Configurations such as vertical pairs are easily implemented with standard hardware to ensure simplified installation and support long term system maintenance requirements. Banner Engineering’s S4B Series Safety Light Curtains are extremely robust with heavy duty, extruded aluminum IP65 rated housing that overcomes optical degradation due to oil and dust accumulation on their windows.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742913776759-cq5dam.web.1280.1280+%281%29.jpg" style="width:100%px" class="fr-fic fr-dib" /></p><h2><strong>#4 Predictive Maintenance and Condition Monitoring of Conveyors</strong></h2><p>On automotive assembly lines, there are a lot of critical devices like pumps and drives, which need to be checked frequently for proper operation. Traditionally, plant managers relied on preventative maintenance schedules provided by a machine’s manufacturer, including regularly replacing machine components on a suggested timeline. However, these timelines are only estimates of when the machine will require service, and the actual use of the machine can greatly affect the reliability of these estimates.</p><p>By monitoring motors, pumps, compressors, fans, blowers, and gearboxes for increases in vibration, problems can be detected before they become too severe and cause damage or unplanned downtime. Vibration and temperature sensors that measure RMS velocity, in inches per second or millimeters per second, and temperature are crucial when setting up condition monitoring systems. Banner’s QM30VT Series sensors have a low-profile design and rigid metal construction that reduces resonant interference and increases surface contact, enabling exceptional levels of accuracy in measuring RMS velocity and temperature. They can detect even slight increases in machine vibration and temperature for early identification of potential problems. </p><p>With Banner's condition monitoring solution, a machine learning algorithm establishes a vibration baseline for the machine. When a machine exceeds its threshold, the wireless temperature and vibration sensor can deliver information to the local user, to a centrally located wireless tower light or to a mobile device via email or text message. The sensor also can send vibration and temperature data to a wireless logic controller or PLC for collection and analysis. The Asset Monitoring Gateway (AMG) with SNAP ID from Banner can collect and analyze this data from up to 20 of the connected sensors. Combine hardware and software to gain a comprehensive condition-monitoring solution. Using the gateway locally or cloud technology online, you can actively track machine performance, conduct predictive maintenance, and improve operational efficiency.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742914185666-cq5dam.web.1280.1280+%282%29.jpg" style="width:100%px" class="fr-fic fr-dib" /></p><h2><strong>#5 Detecting Black Parts on a Black Door Panel</strong></h2><p>Verifying that foam and other components are present on automotive door panels is extremely important to interior trim suppliers because if any part is missing, the quality of the final door assembly is adversely affected. Delivering a bad part to the car manufacturer may result delays or in punitive actions against the Tier 1 supplier. Since door panels are often dark colors such as black or gray, and the foam used to eliminate rattles and provide stiffness is generally black, it can be difficult for standard sensors to differentiate between foam presence and absence due to poor contrast. </p><p>Banner’s Q4X problem-solving triangulation-based laser sensor has no difficulty detecting dark targets on dark backgrounds when there is a height difference. The Q4X provides a reliable sensing solution with best in class excess gain and makes pass/fail judgments based on distance rather than color or reflectivity. A door panel has four areas where foam should be present, so four Q4X sensors are set up to target these areas and confirm proper assembly by the operator. In this case, three targets are verified, but the fourth is missing. A fail signal is sent to alert the operator that the part needs to be reworked before releasing it from the assembly station. Along with reliable sensing on challenging targets, the Q4X is extremely durable with stainless-steel housing that resists mechanical impact, vibrations and overtightening. The setup is simple with clear user feedback on the four-digit angled display and set-up buttons located on the back of the Q4X housing.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742913933770-sensors.jpg" style="width:100%px" class="fr-fic fr-dib" /></p><p><em>This article was written by </em><em>Emmanuel Quellier, Banner Engineering.</em></p>

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