Inline Test Station for LabDisks for AI Based Quality Assurance in Medical Technology

Challenge

A medical manufacturer required a solution for the quality inspection of LabDisks directly within the production line. The system needed to detect transparent structures and identify minimal delaminations within transparent polymer cartridges. Additionally, the precise position of particles and dust had to be determined at µm-level accuracy, while liquids inside the cartridges needed to be differentiated and evaluated qualitatively.

Transparent materials present a particular challenge in optical inspection. Slight delaminations, tiny contaminations, or minimal structural deviations are difficult to visualize due to low contrast and complex light behavior. At the same time, any inspection solution could not cause a bottleneck in manufacturing.

Solution

To automate LabDisk quality assurance, senswork implemented a fully integrated inline inspection station positioned directly within the production cycle. A high-speed digital microscope captures the 150 mm wide transparent LabDisks with a resolution of 10 micrometers. This detailed imaging forms the basis for reliable AI-based analysis.

This image data is then analyzed in real time using Neuralyze®, senswork’s AI-based image processing software. Using trained AI models, the system detects and distinguishes liquids, identifies delaminations, and determines the exact position of particles and dust.

ROI Calculator

Discover the potential cost savings of robotic automation over a 20-year system life

This calculator compares your current manual labor costs against the total cost of owning and operating a robotic system over its 20-year lifespan.

EXPLORE TODAY

Results

By combining high-speed microscopy with Neuralyze® AI software, even the smallest qualitative deviations on transparent surfaces are reliably recognized. senswork has transformed one of the most demanding inspection tasks in medical technology into a quick and easy-to-use process.

A decisive advantage is the system’s speed. With automation, the inspection time is 80% shorter than the cycle time of the preceding sealing process. As a result, quality inspection runs seamlessly inline without affecting production throughput. The solution enables fully automated, high-precision inspection of transparent LabDisks directly within the production cycle, ensuring maximum quality and efficiency.

Learn more about Deep Learning here.