AI-Powered Conformal Coating Quality Inspection
Ensure complete, uniform conformal coating coverage on PCBAs with AI inspection that detects voids, bubbles, and coating defects invisible to traditional systems.
The Challenge of Conformal Coating Inspection
Conformal coating protects PCBAs from moisture, dust, chemicals, and temperature extremes—critical for automotive, aerospace, industrial, and outdoor electronics. Whether you're using acrylic, silicone, urethane, or parylene coatings, the quality of application directly impacts long-term product reliability.
However, inspecting conformal coating is notoriously difficult. The coating is often transparent or translucent, making visual inspection challenging. Defects like air bubbles, dewetting, insufficient coverage, and overspray can be nearly invisible under normal lighting. UV-fluorescent coatings help, but still require expert interpretation to distinguish acceptable variation from true defects.
Traditional AOI systems struggle with conformal coating inspection because the coating creates complex optical effects—reflections, refractions, and fluorescence patterns that rule-based algorithms cannot reliably interpret. This leads to either excessive false rejects or missed defects that cause field failures.
- !Transparent coatings require UV or specialized lighting to visualize coverage
- !Coating thickness variations create optical effects that confuse rule-based systems
- !Keep-out zones around connectors must remain completely free of coating
- !High-mix production requires rapid changeover between inspection recipes
Conformal Coating Applications
Automotive Electronics
ECU boards, sensor modules, and lighting controllers that face harsh under-hood and exterior environments.
Aerospace & Defense
Avionics, satellite systems, and military electronics requiring MIL-spec conformal coating compliance.
Industrial Controls
PLCs, motor drives, and factory automation electronics exposed to dust, chemicals, and vibration.
Consumer Electronics
Wearables, outdoor equipment, and water-resistant devices with selective coating requirements.
Why Overview AI for Conformal Coating Inspection?
Overview's deep learning models are trained to understand the complex visual signatures of conformal coating. Our AI learns what proper coverage looks like across different coating types, thicknesses, and component topographies—distinguishing acceptable variation from defects that threaten reliability.
We support both UV-fluorescent and standard optical inspection, with models optimized for each coating chemistry. Our system can simultaneously verify coverage in required zones while ensuring keep-out areas remain clean—a dual inspection that traditional systems cannot perform reliably.
Coverage Verification
Confirm complete coating coverage on all required areas, detecting voids and thin spots with pixel-level accuracy
Keep-Out Zone Monitoring
Verify connectors, test points, and mechanical interfaces remain free of unwanted coating overspray
UV & Optical Support
Optimized models for both UV-fluorescent and standard visible light coating inspection
Easy Training
Train new models in hours for different coating types and PCBA designs—no deep learning expertise required
Process Monitoring
Track coating process drift with SPC charts, catching nozzle clogs and viscosity changes early
Full Traceability
Store inspection images and results for every board, meeting IPC-CC-830 and MIL-I-46058 requirements
How It Works
Capture
UV or visible light cameras capture high-resolution images of the coated PCBA with optimized illumination
Analyze
Deep learning models evaluate coverage completeness, uniformity, and keep-out zone cleanliness simultaneously
Act
Instant pass/fail decisions with detailed defect mapping for rework or automatic rejection
Conformal Coating Defects We Detect
Our AI models are trained to detect the full spectrum of conformal coating defects that affect long-term product reliability.
Air entrapment in coating
Coating pulling away from surface
Insufficient coating thickness
Uncoated areas in required zones
Coating in keep-out zones
Excessive coating accumulation
Stress fractures in cured coating
Textured surface finish defects
Related Applications
Ready to Perfect Your Conformal Coating?
See how Overview AI achieves 100% conformal coating inspection. Our team will analyze your specific coating and PCBA applications.
Book a Demo