Defect Library
Browse real-world manufacturing defect inspection applications across automotive, electronics, medical devices, batteries, connectors, and more. Each entry shows the defect type and how Overview AI detected it in production.
Automotive
18 cases
Automotive Weld Defect Segmentation
A major automotive manufacturer required a high-speed solution to identify multiple defect types on circular welds.
Axle Component ID Verification
An automotive components manufacturer had to etch component IDs onto axle components before sending on to customers.
Clip Placement in Foam Molds
An automotive supplier needed to detect the presence and correct placement of black clips in foam molds.
Critical Weld Inspection on Brake Pedals
An automotive components manufacturer needed to inspect critical welds on their brake pedal assembly line.
Engine Kit Loose Bolt Check
An automotive OEM was dealing with issues detecting loose bolts in their engine kits.
Gear Tooth & Face Defects
An automotive and aerospace components manufacturer was struggling to identify defects across multiple parts of their gears.
Half Shaft Fit Inspection
An automotive OEM had a challenging inspection problem where they had to detect a soft-set condition in half shafts.
PCB Loose Bolt & Foreign Object Detection
An automotive OEM was conducting a PCB inspection where loose bolts and other foreign objects were present across the board.
Seat Belt Cover Presence
A seating and restraint systems manufacturer produces seats and belts for automotive OEMs.
Seatbelt Guide Gap Check
A seating and restraint systems supplier manufactures seats and belts for automotive OEMs.
Speaker Panel Gap Finder
An automotive components manufacturer produces speaker panels that require a snug fit in the corner to ensure good performance.
Spring & Rivet Assembly Verification
An automotive OEM was assembling a part with multiple springs and rivets.
Stamped Hole Edge Defects
An automotive and aerospace parts supplier was struggling to identify minor defects around the edges of holes on a stamped part.
Stamped Metal Split Finder
We worked with a leading tier 1 automotive supplier who was struggling with inspecting metal stamped parts.
Underbody Overspray Detection
An automotive OEM struggles to consistently detect underbody overspray, particularly around mounting holes.
Valve Material Integrity and Lack-of-Material Inspection
An automotive and aerospace components manufacturer needed a highly precise method to identify "lack of material" defects on the front surface of valves.
Weld Defect for Automotive Supplier
An automotive supplier struggled with manual inspection of welds on their chassis components.
Weld Fault Detection
An automotive supplier was struggling to consistently and accurately detect faulty safety critical welds.
Connectors
14 cases
Automated Connector Assembly and Security Inspection
An electronics manufacturer needed to inspect connectors for proper assembly, with three distinct components to check on each one: the connector itself, the cable, and a security latch.
Automated Soft-Seated Connector Assembly Inspection.
An electronics manufacturer needed to inspect connections in PCBs to ensure they were secure and sufficient for their high quality standards.
High-Density RAM Socket Pin Presence Inspection
An electronics manufacturer needed to verify the presence of pins within high-density RAM sockets on a large PCB.
High-Voltage Wire Braid Defect Detection
An electronics components manufacturer produces high performance electrical wiring for harsh, high voltage environments.
Hose Braiding Wire Gap Inspection
A manufacturer of industrial components required a solution to inspect for wire gaps and bulges on a hose braiding product.
Microscopic PCB Solder Defect and Pad Exposure
An electronics manufacturer required automated inspection for solder defects on a micro-PCB component.
Microscopic PCB Solder Defect and Pad Exposure
An electronics manufacturer required automated inspection for solder defects on a micro-PCB component.
Multi-Component Connector Alignment and Pin Inspection
A high-volume electronics manufacturer needed to perform a high-precision inspection on a multi-pin connector.
NAL Connector Bent Pin Inspection
An automotive and aerospace components manufacturer needed to verify the integrity of terminals inside various types of NAL female connectors.
NAL Female Connector Bent Pin Inspection
A manufacturer needed to verify the integrity of pins inside female connectors to prevent critical assembly failures caused by bent terminals.
Radiator Pinhole Defect Detection
An automotive OEM faced a near impossible quality control challenge in their general assembly area.
Soft-Seated Connector Assembly
An automotive OEM needed to ensure that critical electrical connectors were properly seated and secured in a complex assembly.
Soft-Seated Connectors in Interior Components
An automotive manufacturer needed to ensure that multiple small components, including clips, cables, and connectors, were correctly placed and secured on a complex interior panel (such as a door panel
Winch Component Defect Inspection
An automotive supplier had multiple inspections that needed to be conducted on a single winch component including the castle, pin, spring / clip, and inserts.
Electronics
7 cases
Breaker Base Multi-Check
An electronics manufacturerʼs manual inspection of Breaker Bases involved four touchpoints, leading to errors and high costs.
PCBA Solder Presence Defect Inspection
An electronics manufacturer of PCBAs for electric toothbrushes needed to automate the inspection of tiny solder joints.
Part presence on PCBA for EVs
An electronics supplier in the EV industry faced significant challenges with their inspection process.
Potting Defect on PCBA for EVs
A major PCBA supplier in the EV industry faced significant challenges with their inspection process.
Sensor Surface Scratch Finder
An EV and electrification supplier that builds complex sensor modules reported that sensors are very sensitive to any scratches or surface defects that can impact their installation and sensitivity.
Solder Joint Fault Detection
An electronics manufacturer was struggling with faulty chips leaving their lines, only detected through electronic testing.
Soldering Defect on PCBA for EVs
An electronics supplier in the EV industry faced significant challenges with their inspection process.
Energy Storage
2 cases
Battery Laser Welding Position
A battery manufacturer of portable power bank batteries needed to detect whether laser welds were deviated from the center of the battery.
Copper Busbar Weld Defect Classification
An electronics components manufacturer of high-current copper components, such as busbars or electrical contacts, struggled with quality control of their resistance spot welds.
Food & Beverage
1 cases
Materials
6 cases
Adhesive and Binder Inspection
A textiles manufacturer was struggling to automate the inspection of their products for three different applications: detecting a "binder" on the face (adhesive), checking for the presence or absence
Automated Wood Adhesive Delamination & Crack Detection
A chemicals manufacturer required an automated solution for detecting and measuring adhesive delaminations in wood after accelerated aging tests.
Black-on-Black Membrane Placement Verification
An industrial integrator required a critical inspection to verify the correct placement and presence of a black membrane on a black plastic piece.
Moving Fabric Contaminant and Defect Detection
A textiles manufacturer required an automated system to identify small impurities on their moving fabric.
Textile Missing Edge Coatings
A textile manufacturer required an automated solution for two key quality control applications that were challenging for traditional vision systems.
Textile Yarn Blobs and Tangle Inspection
A textile manufacturer required an automated solution for two key quality control applications that were challenging for traditional vision systems.
Medical
3 cases
Medical Part Contaminant Scan
A medical electronics manufacturer builds equipment for medical applications.
Medical Ring Micro-Scratch Inspections
A medical device manufacturer needed to inspect 1mm-wide surgical rings for subtle scratches and defects.
Medical Tube Keeper Presence and Placement Inspection
A medical device manufacturer required an automated method to verify the presence and absence of a "Keeper" component on a tube.
Metals
7 cases
Metal Casting Defect Detection on Engine Blocks
An automotive OEM was facing significant quality challenges with the metal casting process for their engine blocks.
Pipe Hot Saw Cuts
A metal pipe manufacturer requires precise cuts and bevels on metal pipes, but current methods can lead to myriad defects like (hot) saw cuts, weld caves, open ends, and cracks.
Pipe Micro Cracks
A pipe and tube manufacturing company requires precise cuts and bevels on metal pipes, but current methods can lead to myriad defects like (hot) saw cuts, weld caves, open ends, and cracks.
Pipe Saw Cuts
A materials manufacturer requires precise cuts and bevels on metal pipes, but current methods can lead to myriad defects like (hot) saw cuts, weld caves, open ends, and cracks.
Pipe Weld Caves (Simulated)
A metal pipe manufacturer requires precise cuts and bevels on metal pipes, but current methods can lead to myriad defects like (hot) saw cuts, weld caves, open ends, and cracks.
Platinated Component Surface Defect Inspection
A global manufacturer needed to identify surface defects on various faces of complex platinated pieces.
Steel Strip Coating Defects
An automotive components manufacturerʼs existing vision systems failed to accurately detect subtle coating defects and dual-color products on steel strips, leading to frequent false positives and reli
Pharmaceutical
1 cases
Precision Parts
5 cases
Bearing Micro-Defect Scan
A bearing manufacturer produces industrial-scale bearings for use in a variety of applications.
Detecting Misplaced Components by Robot Arm
An industrial components manufacturer needed a solution to prevent misloaded parts from a robot arm entering their machining process.
High-Precision Tool Scratch Inspection
An automation solutions provider was working with a construction customer that had extremely high precision surveying needs.
Multi-Hole Lever Inspection
A manufacturing supplier produces a number of levers and other components with a variety of holes across a single part.
Multi-Part Component Presence Verification
A manufacturer needed a flexible inspection system to verify the assembly and presence of components across three different parts at a single station.
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