AI-POWERED 3D WELD SEAM INSPECTION

Inspect welds inline—catch defects before rework.

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Increase the quality and profitability of your MIG welding process by automating weld seam inspections for faster problem identification and quicker resolution times. Our fully integrated solution allows you to inspect during manufacturing, not after, without slowing down production, minimizing rework, protecting your customer, and optimizing your use of skilled labour. Augment and optimize your quality control process with AI machine learning tools.

TrueLight 3D-AI Weld Inspection

System Highlights:

  • 3D scanning of the complete weld
  • Production feasible scanning up to 500mm/s at 5kHz+ for defects as small as 0.5mm in diameter (peak performance, requires space to accelerate the tooling up to this speed)
  • Calibrated sensor accuracy across full depth of field of view (FOV)
  • Robot or pedestal mounted scanning for process flexibility
  • Powerful analytics for production and performance
  • Designed for automotive OEM specifications for weld quality
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What Is 3D-AI Weld Inspection?

3D-AI Weld Inspection is an automated quality inspection method that uses 3D imaging and AI to evaluate welds for defects and dimensional inconsistencies. By capturing the weld’s surface profile and key geometric features, the system can detect issues then flag out-of-tolerance welds in real time. It’s designed for inline use, helping manufacturers standardize weld quality, reduce rework and scrap, and keep production moving.

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Core Capabilities

These are some examples of surface defects in weld seams that this automatic 3D visual inspection system is able to identify:

  • Weld length, width, and height
  • Face profile (concavity/convexity)
  • Missing seam or skips (includes ability to sum the total length of weld's discontinuities)
  • Under-cut
  • Porosity
  • Burn-through
  • Spatter (includes ability to toggle detection on/off for spatter-free zones)
  • Throat thickness, cross-sectional area
  • Melt-back
  • Surface crack
  • Rollover
  • Edge notches

Solution Features

Parallel image acquisition and processing to maximize speed of data transmission

Image segmentation to optimize inspection performance and speed of data transmission

Optimized performance using machine learning/AI and traditional toolsets in combination

Easily scaled for small and large applications

Automatic AI image labelling and storage of results for embedded analytics

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Proximity Smart Support™ for real-time, expert support

Ethernet/IP communication is recommended, but alternative configurations such as Profinet are possible.

See 3D-AI Weld Inspection in Action

This interactive simulation demonstrates how TrueLight's 3D-AI Weld Inspection solution uses laser profiling and artificial intelligence to analyze weld geometry in real time. As the weld progresses, the system continuously scans the bead profile, identifies defects from 0.5mm, and provides traceable quality data that can be used to support production and quality improvement initiatives. Use the speed control to simulate inspection rates from 100 mm/s up to 500 mm/s and see how the system maintains reliable defect detection throughout the process.

3D-AI Weld Scan Visualizer | TrueLight
0
Position (mm)
300
Speed (mm/s)
0
Defects found
0.0s
Cycle time
SPEED

Height Map — Top View SCANNING

Laser Profile — Current Slice

Defect Log

No defects yet — seam is clean so far

Proximity Smart Support™ — Live Quality Analytics CONNECTED

SESSION TOTALS
0.00 m
Length inspected
0
Parts scanned
—
First-pass yield
0
Defects found
0.0000
Defects / mm
0.0
Defects / part
TOP 3 DEFECT TYPES
No defects recorded yet.
DEFECTS PER PART — LAST 30 PARTS
Streamed to Proximity Smart Support™ — Traceable, exportable quality data across every part scanned

This simulation is provided for demonstration purposes only and does not represent actual sensor data, inspection results, or production performance. Detection capabilities, inspection speeds, and system performance may vary depending on weld characteristics, application requirements, and operating conditions.

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Proximity Smart Support™

  • Remote support from experts

  • Automation intelligence

  • Part traceability
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BOS Innovations

  • Full-scale automation integration expertise

  • Proven experience with welding systems

  • Trusted turnkey partner
TrueLight 3D-AI Weld Inspection

Turnkey Solution from a Systems Integrator

You do not need to try this on your own, incurring all of the risk, and hoping it works at some level of sustainable performance in production.

TrueLight is here to help. We can include:

  • Part fixturing and tooling
  • System design and safety architecture
  • Optical design
  • Operator interface
  • Software licensing
  • Installation and programming
  • 3rd party safety inspection(s)
  • Training and support for deployment
  • Remote support
  • Basic or advanced analytics for I4.0 and beyond

All customizable to your application.

Download Brochure

Empower your inspection solution with data analytics and inform your process and stakeholders with valuable short-and long-term insights.

Check out our preferred embedded solution: Proximity Smart Support™

TALK TO AN ENGINEER

Challenge us with your parts. We'll validate the approach and help you plan deployment. Contact us today!
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