RoboCT – X-ray inspection for large castings and process optimization

Our solutions are aimed at foundries in die casting (aluminum/magnesium) that manufacture large and geometrically complex components – up to Gigacast/Giga Cast productions. Our technologies are especially relevant for automotive suppliers and OEMs that must meet series requirements for quality, scalability, and stable processes.

RoboCT is an automated inspection solution for large and complex die-cast parts. The system combines 2D X-ray and CT (3D) and delivers reproducible results in serial production:

• AI-based automatic defect detection (ADR): easy to set up, without elaborate parameterization; precise and consistent inspection decisions.
• Flexible for complex geometries: 2D for rapid serial inspections, CT for three-dimensional defect analysis.
• Scalable for large cast parts and Gigacast / Giga Cast components.

The ADR is integrated as an AI-based image analysis in Fraunhofer’s ISAR software and complements classical image processing with machine learning:

• Simple setup: parameterization using only a single threshold – no elaborate training required.
• No reference images needed: saves time during commissioning.
• Pre-trained network: based on simulations and real images; can be augmented with customer-specific data.
• Optional add-on filter: switchable in ISAR, ideal for step-by-step familiarization and validation.
• Result quality: precise, consistent defect detection in X-ray data, with data storage and statistical analysis via ISAR Statistics.

• Structural and body-in-white components (e.g., cross members, battery trays, large die-cast parts)
• Aluminum and magnesium die-castings in automotive series production (OEMs and suppliers)
• Large-format components in Gigacast / Giga Cast concepts

Cast Control is an independent software solution for linking die-casting process data with inspection results (X-ray/CT).

• Root-cause analysis: identifies systematic sources of defects and makes correlations transparent.
• Reduce scrap sustainably: data-driven optimizations increase process stability.
• Complements existing quality and production processes without requiring RoboCT.

Is Cast Control required for RoboCT?

No. Both products can be used independently and can be optionally combined.

What does ADR do in RoboCT?

AI-based automatic defect detection with easy setup and stable results – without complex parameterization.

When should I use CT instead of 2D X-ray?

CT for complex geometries and 3D defect analysis; 2D X-ray for fast inspections in serial production.

How does Cast Control reduce scrap?

By linking process and inspection data, causes are identified and actionable recommendations for elimination are provided.