Resonant testing for quality control and process monitoring

Challenge

Quality Control that keeps up with production speed

In high-volume manufacturing, production speed often comes at the cost of quality assurance. Traditional inspection methods are too slow, expensive, or intrusive to be integrated inline. As a result, many production lines rely on limited sampling or offline testing, which leads to:

• Missed defects and reduced product quality;
• Higher scrap rates and material waste.

To move towards zero-defect manufacturing, we need quality control solutions that are as fast and scalable.

Project goals

Inline Vibrational Quality Control Demonstrator

This project aims to develop a demonstrator for inline vibrational quality control. A solution that delivers real-time insights into product integrity without disrupting production speed.

Our approach enables the following:

• Fast and reliable testing based on vibration technology;
• Better detection of both hard and soft defects, such as porosity, cracks, cavities, microstructural changes, residual stress, and creep;
• Continuous monitoring of production line performance over time;
• AI-driven data analysis for intelligent defect detection and trend prediction;
• Broad applicability across materials (metals, composites, ceramics, polymers) and manufacturing processes (additive manufacturing, milling, casting, injection moulding, etc.).

The inspection solution will be fast, cost-effective, and user-friendly, enabling 100% part screening without slowing down production.

By leveraging vibration-based testing, the system will accurately determine the structural integrity of each part and provide an instant PASS/FAIL decision directly on the production line.