End-of-line testing with CT: added safety during commissioning, reduced risk in the field
Integrate industrial computed tomography into your end-of-line inspection as a temporary safeguard. Detect hidden defects in real time: fully automated, AI-powered and cost-effective, regardless of batch size.
An end-of-line test (EOL test) is the final quality check at the end of a production line. The aim of end-of-line testing is to ensure that every product meets the required standards before it leaves production. Various testing methods have become established in industrial production and manufacturing. These range from visual inspection and leak tests to electrical functional testing. But what happens if the faults lie inside the component and conventional end-of-line tests cannot detect them?
This is precisely where Microvista comes in. Not as a manufacturer of permanent EOL testing systems, but as a service provider for CT-based end-of-line testing, which can be deployed temporarily, quickly and without the need to purchase equipment.
An end-of-line test (EOL test) is the final quality check at the end of a production line. The aim of end-of-line testing is to ensure that every product meets the required standards before it leaves production. Various testing methods have become established in industrial production and manufacturing. These range from visual inspection and leak tests to electrical functional testing. But what happens if the faults lie inside the component and conventional end-of-line tests cannot detect them?
Not every manufacturing process requires continuous CT inspection at the end of the line. However, there are phases in which the residual risk is too high to rely solely on existing testing methods. This is the case, for example, during series production start-up, following a tool change or when there is an unexplained rise in the scrap rate. Whether in our CT laboratory or directly on your production lines, with the ScanExpress, a mobile industrial CT scanner, you can obtain reliable data rather than relying on assumptions. This ensures the production line is specifically safeguarded until the process is demonstrably stable.
When do you need a CT-based end-of-line inspection?
In a stable, robust process, quality is ideally achieved within the process itself. Nevertheless, EOL testing remains indispensable where residual risks are high or the consequences of faults are critical. CT testing technology really comes into its own during temporary risk phases. As a rule, it is not used as a permanent solution, but rather as a targeted risk mitigator and catalyst for process stabilisation.
Typical triggers for the use of CT-based EOL testing:
- Start-up (SOP): During the ramp-up phase, manufacturing processes have not yet been fully mastered. CT provides rapid feedback on actual component quality and helps to stabilise the process at an early stage.
- After a tool change: New or reworked tools may cause unforeseen deviations. A temporary 100% inspection or random sampling provides assurance before production continues.
- After a process fault: If a fault has occurred, it must be determined whether any components are affected and, if so, how many. CT quickly reveals the effects in a non-destructive manner.
- In the event of a noticeable increase in scrap rates: If scrap rates rise without any apparent cause, CT provides the data needed to identify the root causes of the faults and rectify them effectively.
- When changing suppliers: New intermediate products or raw materials can alter the failure pattern. EOL testing with CT ensures quality during the transition phase.
- To identify the cause: If other testing methods report anomalies but the cause remains unclear, CT identifies the location, cause and extent of the defect in a single step.
- As a bridge: Until process capability is demonstrated, CT bridges the critical phase.
CT as a learning tool: Test. Understand. Improve. Reduce.
Most end-of-line testers provide a binary result: OK or NOK. This is sufficient for selection, but not for optimisation. CT-based EOL tests often go a step further. They not only highlight faults, but also explain them.
1. Check
Reliable OK/NOK sorting through AI-based defect detection. Every component is thoroughly inspected to identify even internal defects that are not visible from the outside.
2. Understand
The CT data not only shows that there is a fault, but also where it is located, what it looks like and how frequently it occurs. This provides clarity regarding the condition of the test specimen.
3. Improve
Based on these findings, process parameters can be adjusted in a targeted manner. By feeding the CT data back into the manufacturing process, data-driven process optimisation is made possible.
4. Reduce
Once the process has stabilised and process capability has been demonstrated, the use of the CT will be scaled back. The CT will remain in place for as long as it is needed, without incurring any ongoing costs.
This approach sets Microvista apart from suppliers of permanent inspection systems: we do not sell equipment that you are obliged to run continuously. Instead, we provide a service that you can deploy as and when required and discontinue as soon as your process allows.
Advantages of CT inspection technology for end-of-line testing
Conventional end-of-line (EOL) inspections – whether visual inspections, leak tests or electrical functional tests – generally only detect surface or functional parameters. Internal defects often remain hidden. An end-of-line inspection using CT technology specifically complements existing test systems where these reach their limits.
Reliable inspection
CT makes internal structures visible. Pores, voids and cracks are reliably identified – ensuring an inspection that efficiently detects defects.
100% non-destructive
Every inspected component is ready for delivery. No rejects resulting from the inspection itself – ideal for the manufacture of high-quality components.
Automation through AI
AI-based defect detection enables automated pass/fail sorting. Automating inspection processes has never been easier.
CT-based end-of-line testing: When is it the right choice – and when is it not?
We don’t want to sell you a service you don’t need. That’s why we’ll also tell you when a CT scan is the right choice as an end-of-line test – and when other testing methods are more suitable.
A CT scan is the right choice if:
- defects are internal and cannot be detected from the outside (visual inspection not possible)
- which is intended to check for proper functioning, completeness or correct assembly – when closed
- other methods are of limited use, whereas a CT scan can identify the location, cause and extent of the fault
- there is a wide variety of variants and the test system must be quickly adaptable
- temporary safeguards are required during critical phases
Other methods are more suitable if:
- only superficial, visual defects are relevant (visual inspection is quicker and cheaper in this case)
- the fault can be clearly identified using a simple gauge or sensor system
- extremely high volumes of low-cost products are produced at very high speeds & there are no critical internal characteristics
This honesty is part of our free consultation. If CT isn’t the best solution for your testing requirements, we’ll let you know.
Sectors requiring end-of-line testing using CT
Our CT-based end-of-line inspection meets the standards and requirements of demanding industries.
Automotive & E-mobility
- Hairpin stators
- Battery compartment
- Lightweight chassis components
- Transmission components
Foundries
- Die-cast aluminium
- Cast iron components
- Pore analysis
- Wall thickness measurements
Electronics industry
- Printed circuit boards (Electronic)
- Lithium-ion cells
- Weld inspection
- Solder joint analysis
Medical technology
- Surgical instruments
- Precision components
- Sterile packaging
- Implants & Dentures
Laboratory or ScanExpress – which option is right for your EOL testing?
EOL testing in the CT laboratory
You send your components to our laboratory in Blankenburg. We scan them, analyse them using AI, and make the results available to you online. This model is particularly suitable if:
- you need sample testing or batch approvals
- the components are portable and there is no time pressure on a minute-by-minute basis
- you wish to use the findings primarily to identify causes and optimise processes
EOL testing with the ScanExpress:
The ScanExpress is a mobile CT system that can be brought directly into your production hall. The analysis is carried out automatically on site. This model is particularly suitable if:
- a temporary 100% inspection or a close-meshed sampling procedure is required directly on the production line
- shipping the components would be too costly, too slow or too risky
- you need to be able to quickly secure the site during the start-up of production or following a process fault
- where cycle time is critical and results are needed immediately on the production floor
In both cases, the same applies: no equipment purchase, no long-term commitment. You pay for the service, not for a machine.
How to get started with EOL protection using Microvista
Consultancy & Feasibility
Together, we analyse your components and testing requirements. We define the optimal testing strategy for your manufacturing process and tailor the test environment to your needs.
Scan & AI Analysis
Your components are scanned in our CT laboratory. The AI-based analysis automatically detects defects and reliably classifies them as OK or NOK – with optimised cycle times for your mass production.
Report & Integration
You will receive detailed test reports with full documentation. In addition, we will show you how the data can be used to optimise your processes. This will enable you to reduce your use of CT in the future.
Get your free consultation now!
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Contact person for immediate support
Jonas Wengerodt
Sales Manager
Dr. Robin Höhne
CEO | Microvista GmbH
Frequently asked questions about end-of-line testing using CT
Conventional end-of-line tests usually only check surfaces or electrical functions. CT inspection technology enables a complete inspection of the interior of components – ideal for the reliable detection of defects in castings, welds and complex assemblies in industrial manufacturing.
No, Microvista only offers CT-based end-of-line inspection as a service. Microvista supports you either through its in-house CT laboratory or with the mobile ScanExpress on-site. This approach is deliberately temporary: CT is used to safeguard critical phases and is scaled back once the process has stabilised.
Yes. By utilising AI and automated testing processes, our high-performance testing systems achieve fast turnaround times. Depending on the component size and testing requirements, even large quantities can be tested cost-effectively – optimising cycle times is part of our consultancy service.
Our CT inspection reliably detects pores, voids, cracks, inclusions, assembly deviations and variations in wall thickness. Defects in printed circuit boards in the electronics industry and critical areas in medical technology are also reliably identified.
The comprehensive quality inspection carried out at the end of the production line ensures that faulty components are identified before they reach the customer. This reduces returns, prevents costly product recalls and ensures the long-term safety of the products.
Where only surface defects are relevant, the defect pattern can be detected using simple sensors, or extremely high volumes of non-critical products are produced at very high cycle rates. In such cases, other methods are more cost-effective.
Our CT-based EOL tests are extremely versatile – whether for single units, small batches or large-scale production in the automotive industry. The test parameters can be quickly adapted to different component geometries and materials. Customers in the automotive sector, in particular, value this flexibility in adapting to changing testing requirements.
*The commitment to provide the service within 48 hours is subject to the granting of an operating licence in the relevant country. Furthermore, meeting this deadline requires transport links that enable travel within the specified timeframe.