Next-Gen Quality Control: ZDZW’s Collaborative Innovation in Injection Molding
Technology Being Tested
The ZDZW project, through Pilot 1, is focused on implementing and testing advanced technologies for improving the visual and dimensional inspection of thermoplastic parts produced by injection molding. The technologies used include:
Surface Anomaly Detector: This AI-powered system detects surface defects in real-time, identifying anomalies such as scratches, dents, or other imperfections on thermoplastic parts.
Volumetric Inspector: Utilizing 3D imaging technology, this tool assesses the internal and external integrity of parts, identifying dimensional deviations or internal defects that may not be visible to the naked eye.
These technologies are integrated into a cohesive inspection system that operates inline, providing real-time feedback and ensuring consistent product quality while reducing manual inspection errors.
Use case in a Nutshell
This collaboration is between two key project partners, GLN PAST (the pilot) and ITI – Instituto Tecnológico de Informática (the tech provider). The collaboration focuses on deploying the Surface Anomaly Detector and Volumetric Inspector to enhance the inspection process and ensure zero-defect production. This partnership has led to improvements in the manufacturing process and product quality.
About the collaboration partners
GLN PLAST: An end-user specializing in the mass production of thermoplastic parts via injection molding. GLN PAST aims to improve efficiency, reduce defects, and enhance product quality in its production processes.
ITI – Instituto Tecnológico de Informática: A technology partner specializing in artificial intelligence and vision systems. ITI brought its expertise in AI-enhanced image processing and 3D imaging for manufacturing applications
Description of the Collaboration
Technology Integration
AI-powered vision systems, 3D imaging, and thermal cameras were implemented into the existing production line to automate and enhance the inspection of thermoplastic parts.
Automation and Efficiency
The project replaced manual inspection processes with automated systems that provide real-time feedback, increasing the speed and accuracy of inspections while reducing human error.
Real-Time Feedback
By incorporating real-time feedback mechanisms, the system allows for immediate corrective actions during the production process, ensuring faster detection and resolution of any issues.
Results of the Colaborration
Energy Consumption
Reduced by 9–12%.
Greenhouse Gas (GHG) Emissions
Decreased by 8–12%.
Waste and Rejection Rates
Lowered by 2–3%.
Productivity
Increased by 7–10%.
Overall Savings
Achieved 3–5% in cost reductions.
Testimonials
“The integration of advanced inspection technologies into our production processes has been transformative. The real-time feedback and automation have not only enhanced our product quality but also streamlined our operations, leading to significant cost savings”
Project info:
ZDZW is a project funded by the European Union’s Horizon Europe research and innovation programme under Grant Agreement No. 101057404. With a consortium formed by 27 partners, ZDZW will develop Digitally Enhanced Non-destructive Inspection Services for globally competitive, clean, and sustainable production in European and Global Manufacturing.
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