Plastics
Ultrasonic Weld Verification
Real-time AI thermal inspection that reveals weld integrity at every joint, ensuring stronger bonds, fewer failures, and consistent product quality.
The Challenge
In ultrasonic plastic welding, precision is everything. Even minor issues like part misalignment, surface gaps, material inconsistencies, or incorrect weld settings (amplitude, time, or pressure) can lead to incomplete fusion, weak bonds, trapped voids, or contamination.
Traditional inspection methods rely on post-process checks or destructive testing, which can miss subtle variations in weld quality. Left undetected, these defects result in scrap, costly rework, warranty claims, and potential field failures.
Our Solution
Eigen’s AI-powered thermal inspection system continuously monitors individual weld points during the ultrasonic welding process.By capturing thermal signatures immediately after each weld, it visualizes fusion quality and heat distribution in real time, helping operators see what the human eye can’t.
In-line thermal cameras paired with AI models detect anomalies across the full weld area, pinpointing where bond strength or consistency may be at risk. Data is processed in OneView Cloud, where engineers can view severity scores, defect locations, and trend data for continuous quality improvement.
The system integrates directly with the welder’s PLC, enabling instant operator alerts, process parameter correlations, and seamless MES communication. Over time, the accumulated defect data builds a process intelligence layer that helps engineers fine-tune weld settings, minimize variability, and maintain product conformance—all while reducing the need for destructive testing.
Operator view vs Eigen view
A side-by-side look at how Eigen’s vision system exposes weld inconsistencies invisible to manual inspection.
Benefits
In-Line Defect Detection: Identifies weak or incomplete welds directly during production, preventing defective parts from advancing downstream.
Comprehensive Classification: Detects and classifies multiple defect types - including incomplete fusion, weak bonding, and misalignment, with precise defect location mapping.
Real-Time Alerts: AI-driven alarming system flags severity-based thresholds to prompt immediate corrective action.
Adjustable Quality Limits: Enables customer-defined acceptance limits based on live production data, reducing false positives and evolving with changing requirements.
Full-Part Coverage: Supports multiple thermal cameras for 100% weld coverage, delivering instant visual feedback and process optimization opportunities.
The Challenge
In ultrasonic plastic welding, precision is everything. Even minor issues like part misalignment, surface gaps, material inconsistencies, or incorrect weld settings (amplitude, time, or pressure) can lead to incomplete fusion, weak bonds, trapped voids, or contamination.
Traditional inspection methods rely on post-process checks or destructive testing, which can miss subtle variations in weld quality. Left undetected, these defects result in scrap, costly rework, warranty claims, and potential field failures.
Our Solution
Eigen’s AI-powered thermal inspection system continuously monitors individual weld points during the ultrasonic welding process.By capturing thermal signatures immediately after each weld, it visualizes fusion quality and heat distribution in real time, helping operators see what the human eye can’t.
In-line thermal cameras paired with AI models detect anomalies across the full weld area, pinpointing where bond strength or consistency may be at risk. Data is processed in OneView Cloud, where engineers can view severity scores, defect locations, and trend data for continuous quality improvement.
The system integrates directly with the welder’s PLC, enabling instant operator alerts, process parameter correlations, and seamless MES communication. Over time, the accumulated defect data builds a process intelligence layer that helps engineers fine-tune weld settings, minimize variability, and maintain product conformance—all while reducing the need for destructive testing.
Operator view vs Eigen view
A side-by-side look at how Eigen’s vision system exposes weld inconsistencies invisible to manual inspection.
Benefits
In-Line Defect Detection: Identifies weak or incomplete welds directly during production, preventing defective parts from advancing downstream.
Comprehensive Classification: Detects and classifies multiple defect types - including incomplete fusion, weak bonding, and misalignment, with precise defect location mapping.
Real-Time Alerts: AI-driven alarming system flags severity-based thresholds to prompt immediate corrective action.
Adjustable Quality Limits: Enables customer-defined acceptance limits based on live production data, reducing false positives and evolving with changing requirements.
Full-Part Coverage: Supports multiple thermal cameras for 100% weld coverage, delivering instant visual feedback and process optimization opportunities.
The Challenge
In ultrasonic plastic welding, precision is everything. Even minor issues like part misalignment, surface gaps, material inconsistencies, or incorrect weld settings (amplitude, time, or pressure) can lead to incomplete fusion, weak bonds, trapped voids, or contamination.
Traditional inspection methods rely on post-process checks or destructive testing, which can miss subtle variations in weld quality. Left undetected, these defects result in scrap, costly rework, warranty claims, and potential field failures.
Our Solution
Eigen’s AI-powered thermal inspection system continuously monitors individual weld points during the ultrasonic welding process.By capturing thermal signatures immediately after each weld, it visualizes fusion quality and heat distribution in real time, helping operators see what the human eye can’t.
In-line thermal cameras paired with AI models detect anomalies across the full weld area, pinpointing where bond strength or consistency may be at risk. Data is processed in OneView Cloud, where engineers can view severity scores, defect locations, and trend data for continuous quality improvement.
The system integrates directly with the welder’s PLC, enabling instant operator alerts, process parameter correlations, and seamless MES communication. Over time, the accumulated defect data builds a process intelligence layer that helps engineers fine-tune weld settings, minimize variability, and maintain product conformance—all while reducing the need for destructive testing.
Operator view vs Eigen view
A side-by-side look at how Eigen’s vision system exposes weld inconsistencies invisible to manual inspection.
Benefits
In-Line Defect Detection: Identifies weak or incomplete welds directly during production, preventing defective parts from advancing downstream.
Comprehensive Classification: Detects and classifies multiple defect types - including incomplete fusion, weak bonding, and misalignment, with precise defect location mapping.
Real-Time Alerts: AI-driven alarming system flags severity-based thresholds to prompt immediate corrective action.
Adjustable Quality Limits: Enables customer-defined acceptance limits based on live production data, reducing false positives and evolving with changing requirements.
Full-Part Coverage: Supports multiple thermal cameras for 100% weld coverage, delivering instant visual feedback and process optimization opportunities.
