Detect every flaw with AI surface inspection that identifies
micro-defects in real time, and reduces rework costs.
Our Clients
Every scratch, void, or surface irregularity, whether millimeter-sized or barely visible, threatens product integrity and customer satisfaction. Human inspection lacks the speed and precision to catch defects of all types and sizes reliably. Our AI-powered surface defect detection solution automatically identifies anomalies across materials, detecting defects as small as 0.1mm with 99%+ accuracy.
Softweb Solutions holds over 21 years of experience in delivering industrial automation, AI surface inspection solutions, and operational risk management. Using advanced computer vision and deep learning, our system automatically classifies and locates defects including corrosion, burrs, stains, and dimensional deviations. With proprietary algorithms trained in millions of defect images, we deliver faster inspections, reduced waste, and zero-defect quality assurance that protects your bottom line.
We deploy deep learning models trained on metal-specific defect patterns to micro-cracks, corrosion, and surface inconsistencies in real-time. Our models process images at line speed, flag deviations instantly, and integrate with sorting equipment. From camera to software, each element is customized to your business needs.
We deploy real-time glass surface scanners that identify micro-defects across wide substrates. Our machine learning model distinguishes between surface and subsurface defects, ensuring precision across float glass with instant rejection control. Organizations can minimize customer returns and maintain premium product standards.
We implement AI vision systems that detect surface irregularities, color shifts, and pattern misalignments on ceramic products at production speeds. Our models analyze texture, finish uniformity, and dimensional accuracy, to flag substandard tiles automatically. This results in reduced waste, improved aesthetic consistency, and faster quality validation.
Our AI inspection solutions are integrated within panel lines to detect defects under complex patterns and finishes. Systems analyze and detect knots, grain irregularities, surface damage, and coating defects on wood and metal panels using multi-spectral imaging. Businesses achieve faster inspection cycles, consistent grading accuracy, and reduced labor costs.
We use machine vision to inspect leather and textiles that identify defects in weave, color, and texture instantly. Real-time processing enables immediate defect marking and quality classification. This results in operational gain, reduced waste, improved roll quality, and consistent material specifications.
Our systems detect coating defects, wrinkles, and air bubbles on laminated or foil surfaces with reflective materials moving at high speeds. Models analyze material at production speed, flag anomalies instantly, and trigger web breaks or rejection. This technology minimizes material waste, ensures print quality, and maintains production efficiency.
We conduct specialized inspection for battery electrode foils that ensure uniform coating, detect micro-scratches, and eliminate defects that could compromise battery performance and safety. Our ultra-high-resolution imaging combined with AI models captures anomalies in real-time, measures defect density and provides material qualification reports. This results in improved safety standards, reduced warranty claims, and enhanced cell performance.
Our wide-area inspection systems capture defects across large-format materials using multiple synchronized cameras and intelligent image stitching. Processing algorithms handle complex patterns and varying lighting conditions. Manufacturers can ensure complete surface coverage, faster inspection cycles, and consistent quality across entire production runs.
We implement a final inspection platform that verifies assembled components for surface quality, dimensional accuracy, and completeness. Multi-angle imaging captures all visible surfaces while AI classifies defects by severity. This provides comprehensive quality validation, reduces field failures, and ensures customer satisfaction.
Achieve zero-defect with AI-powered surface inspection that eliminates costly reworks
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The initial step takes pictures of surfaces through the use of high-resolution cameras so that all details are captured. Advanced lightening methods, such as diffuse, directional, and structured light, detect defects that are not visible to normal imaging. These images provide the data required for detailed visual inspection and defect analysis.
The captured images undergo detailed analysis using deep learning models that are trained on millions of defective examples to identify defects in real-time. Convolutional neural networks identify surface anomalies by learning hierarchical feature patterns unique to each defect type. Each anomaly is marked for further classification based on type and severity.
Once surface issues are identified, they are sorted into categories defining severity and type. Deep learning models evaluate defective characteristics and provide production teams with actionable intelligence. This process enables the team to distinguish between minor cosmetic blemishes and critical flaws, prioritizing inspections and rework efficiently.
The results automatically trigger predefined actions matched to defect severity and type. Real-time notifications enable automated sorting, diverting defective items for re-inspection protocols. This ensures only defect-free products proceed down the production line.
90%+ defect detection accuracy by identifying even micro-scale surface anomalies
50% faster inspection cycles with automated systems without quality compromise
70% reduction in manual labor by releasing quality personnel for strategic analysis
Improved yield and product reliability by identifying defect at the initial stage
Catch every surface flaw with precision inspection technology now
Start your AI inspection journeyMicroscopic surface defects on semiconductor wafers create circuit failures and catastrophic yield losses worth millions. Our AI surface inspection systems capture even microscopic inconsistencies. This technology improves wafer and chip quality, reducing rework cycles.
Undetected metal surface defects in automotive manufacturing impact automotive brand perception and vehicle longevity. Our surface defect detection solutions identify micro-dents, scratches, and uneven textures. This ensures precision and visual perfection for every vehicle.
Electronics manufacturing demands precise identification of microscopic defects on PCBs. Unseen PCB surface defects can cause functional failures. Our micro-defect identification technology evaluates boards and components throughout assembly, identifying problems at speeds to match production demands. This results in higher product reliability and improved manufacturing efficiency.
Fabric production generates continuous material flows where defects must be detected and marked instantly. Our textile inspection systems identify weave defects, color variations, and fabric damage while materials move at full production speeds. Textile manufacturers achieve consistent quality grading, optimize material utilization, and reduce customer complaints.
Packaging quality directly impacts brand perception and product protection. Our inspection solutions verify label placement, print quality, surface consistency, and structural integrity for every package. Brands maintain visual appeal, ensure regulatory compliance, and minimize customer returns through automated quality validation.
The inspection system continuously improves with new defect types and production changes. They identify new defect patterns and adjust themselves to the changing environment while maintaining accuracy.
Enable faster inference on the factory floor with scalable analytics in the cloud. Real-time defect detection is conducted on local hardware at production speed while handling computationally intensive analytics. This hybrid model creates a responsive, unified inspection network.
Our systems operate as a native component integrates with existing digital infrastructure including digital twins, predictive maintenance, and MES/ERP systems. Seamless data exchange with existing manufacturing infrastructure enables holistic quality management and automated processing.
Our detection setup easily expands multiple production lines or facilities. Modular architecture supports incremental deployment from single inspection stations to enterprise-wide quality networks. This flexibility supports both pilot deployments and global rollouts.
Reduces material waste and energy use by minimizing rework and defects. Our inspection solutions identify defects at an early stage and prevent processing of defective materials through subsequent production stages. This lowers energy consumption and supports environmental responsibility goals.
AI-based surface defect detection is an automated inspection process that identifies imperfections on manufactured parts or materials using image analysis. It relies on advanced imaging and pattern recognition to spot even minute irregularities. The result is faster, more consistent, and objective quality control across production lines.
A computer vision system uses cameras and lighting setups to capture detailed images of a surface. These images are then analyzed to identify variations in texture, color, or structure that indicate a defect. The system compares live visuals to reference standards and highlights deviations for review or action.
Surface defect detection systems can identify a wide range of imperfections, including scratches, dents, stains, pits, cracks, and uneven coatings. They are also capable of detecting subtle issues such as color inconsistencies and micro-defects invisible to the human eye. The system adapts to different product types and inspection needs.
Automated surface inspection provides greater consistency and precision than manual inspection. It eliminates fatigue, human bias, and variability, maintaining the same accuracy level across long shifts. Many manufacturers report a significant improvement in defect detection rates and a reduction in false rejections.
Yes. These systems are designed to inspect metals, glass, ceramics, plastics, textiles, and more. The inspection setups such as lighting, camera angle, and detection parameters are calibrated based on the material’s surface texture and reflectivity to ensure reliable results.
The inspection system can be integrated directly onto conveyor belts or assembly lines without major changes to existing equipment. It communicates with factory control systems to mark, sort, or remove defective parts automatically. This seamless integration maintains production speed while enhancing quality control.
Yes. Surface defect detection solutions are now available in modular formats that scale to different production volumes and budgets. Manufacturers can start small, deploy the system on key lines, and expand as production grows, making it a practical investment even for smaller operations.
Automated inspection reduces rework, scrap, and downtime by identifying defects early in the process. It helps maintain consistent product quality and optimizes resource use. Over time, data from inspections also provides valuable insights for process improvement and predictive maintenance.
Redefining surface inspection for zero-error precision
Partner with us to explore intelligent inspection systems that elevate precision, eliminate defects, and set new quality benchmarks.
