Optical inspection for large EPP partsIdentify local deformation in seconds. Zero critical-dimension complaints.
DBM deploys high-throughput optical inspection to address thermal shrinkage and local warpage in foam parts. Switch product recipes in seconds, scan the full exterior contour and highlight out-of-tolerance regions, connecting complete inspection data with the tooling and process improvement loop.
Median 1106.3 mm
Application outcomes
Proven Quality Gains & Zero Critical-Dimension Complaints Since Launch
Dimensional Delivery Complaints
From 1–3 assembly-dimension disputes per month to zero dimensional delivery complaints post-deployment.
Shift Inspection Throughput
Delivers over 8× the throughput of manual inspection per shift, eliminating line-end packaging bottlenecks.
Per station, for the same product over an equivalent shift, compared with one manual inspector.
Single-Part Inspection Time
Returns dimensional results in ~3 seconds. Automatically evaluates length, width, local protrusions, and warpage with audio-visual alarms and color-coded poka-yoke defect mapping.
Optical inspection · Local deformation
Why Caliper Spot-Checks Miss Assembly Interference on Foam Parts
Material behavior
EPP is a microcellular expanded polymer. Anisotropic shrinkage during cooling and demolding can cause local bulges, wavy edges or diagonal warpage. A single-point reading can miss an out-of-tolerance peak, leading to clip-fit or sealing interference.
Full-contour inspection
The station continuously captures the exterior contour and marks local deviations in red. A 1106.3 mm median can be within tolerance while a 1107.5 mm local peak exceeds the limit by 0.8 mm. Evaluate both median and local tolerance to prevent false acceptance.
One-Click Recipe Switching & Tolerance Assignment
Preload dimensional tolerances and scan references for each product and cavity. Scan the code to load the correct standard and prevent drawing or tolerance mix-ups.
Non-Contact Rapid Positioning & Scanning
Placing the part triggers scanning without contact pressure that could deform soft foam. Capture the long side, short side and boundary contour.
Real-Time Tolerance Evaluation & Defect Heatmapping
Red NG callouts display exact deviations (e.g., +0.8 mm), enabling operators to locate out-of-spec zones instantly without manual marking.
Immediate OK Release & Segregated NG Tracking
OK parts proceed to packaging and order preparation. Mark and segregate NG parts with machine and batch associations. Keep separate remeasurement and rework records to close the inspection and disposition loop.
Long side · Median
1106.3 mmLong side · Local maximum
1107.5 mmShort side · Median
1105.5 mmHere the long-side upper limit is 1106.7 mm. The local maximum exceeds it by 0.8 mm. Staff review the indicated location and handle the result.
Digital quality control · Full inspection records
Retain original dimensions. Trace initial and rework inspections separately.
Retain original per-part readings and decisions throughout their lifecycle with tamper protection. Separate initial and rework archives support batch quality management and IATF 16949 traceability needs.
Complete original dimensional records
Preserve original per-part measured values and decisions throughout their lifecycle, protected against tampering, for dimensional review and quality traceability.
Separate initial and rework data
Archive rework reinspections independently without offsetting initial defects, preserving the true first-time yield (FTY).
Batch quality dashboard
Automatically aggregate dimensional variation by day and shift to support tooling adjustment and process review.
Initial inspection
Retain the initial readings and decision- Long side · Local maximum
- 1107.5 mm
- Short side · Median
- 1105.5 mm
Reinspection after rework
Check dimensions again after reworkReinspect reworked parts and independently archive readings, decisions and disposition with machine and batch associations. Rework results do not offset initial defect counts.
Production feedback · A connected process loop
From Deformation Patterns to Batch Cpk Verification
Associate dimensional deviations with tooling, molding parameters and production batches, and send the findings directly to molding staff. Use deformation patterns to guide investigation and subsequent batch distributions to verify improvement.
Locate the deformation pattern
Identify progressive edge shrinkage or local ejector-related deformation to guide process and tooling investigation.
- Patterns to identify
- Edge shrinkage trends and local deformation positions
Feed Deviations Back to Molding
Link dimensional deviations directly with tool IDs, steam temperatures, and pressure settings to feed corrective data back to the molding line in real time.
- Linked information
- Dimensional deviations, mold identifiers and molding parameters
Respond to dimensional drift
Process engineers use dimensional drift trends to fine-tune holding and cooling time or mold-opening timing, addressing uneven mold temperature.
- Targeted adjustments
- Holding and cooling time; mold-opening timing
Verify control through distributions
Review subsequent batches of critical-dimension distributions and Cpk to confirm the process window has returned to control.
- Verification results
- Critical-dimension distributions and batch Cpk
Use full-inspection data to identify dimensional drift, then follow up with on-site process calibration and batch Cpk verification to connect inspection, production and quality review.
Manufacturing delivery · Dimensional control
Build dimensional control from molding to shipment.
Connect high-throughput dimensional inspection, production feedback and batch verification after molding to support consistent, low-defect EPP / EPS structural-part delivery.
Keep the end of the line moving
Match inspection to post-molding operations, reducing waiting and work-in-progress piles that can compress and damage soft parts.
Flag tooling wear
Monitor dimensional variation across cavities to warn of blocked steam vents and mold deformation.
Meet automotive-grade audit requirements
Generate batch dimensional histograms and Cpk reports with tamper-proof data and end-to-end traceability, supporting OEM on-site inspections and stringent automotive-grade quality audits.