Case study: The benefits of wavefront sensing in material inspection

Introduction

In this case study, we explore the application of a wavefront sensor within the setting of the material inspection process of a laboratory equipment manufacturer. Wavefront sensors are frequently used in metrology and to test the quality of optical systems, with special attention to their lenses, in order to detect any potential defects. Implementing a wavefront sensor into the material inspection process increases its capabilities to near imperceptible deformities before they can reach the manufacturing line. 

Background

An inspector’s goal is to ensure that no defective materials become part of the final product, guaranteeing a high level of quality for the client, and preventing the future costs and reputation damage that the manufacturer would have to face. To improve their process, the company decided to incorporate a wavefront sensor to the dedicated equipment inventory. 

Objective

The primary objective is to introduce inspectors to wavefront sensing technology, and how it can enhance their work capabilities. By integrating the SEBI RT1000 into the material inspection process, the company aims to detect critical deformities in the materials used for the sensible equipment they manufacture in a quick and efficient manner.

Implementation 

1. Wavefront Sensor Selection: The company selects the SEBI RT1000 wavefront sensor for its simplicity and effectiveness in detecting aberrations invisible to the eye. This sensor uses a combination of an electrically tunable lens and a proprietary imaging algorithm / technique, to obtain data from two out-of-focus images.
2. Material Inspection: Materials inspectors analyze the physical properties of the object of interest to detect any defects that can put the quality of the final product at risk. The data collection is done in real-time, allowing the inspectors to conduct direct observations under a variety of circumstances to test how the material reacts to them.
3. SEBI® Analyzer Suite: Data Analysis dedicated software that processes the wavefront sensor data, reconstructing the information obtained and identifying aberrations. Inspectors analyze the data to understand what aberrations are present and how they came to be.

Results

Integrating a wavefront sensor into the materials inspection process yields several positive outcomes:  

• Reduced inspection times 

• Improved detection of microscopic defects thanks to an increased resolution 

• Larger amount of data collected 

• Real-time observations under experimental circumstances 

• Increased effectiveness of the quality inspection tests 

Conclusion

The successful implementation of a wavefront sensor in the material inspection process improves the performance and experience of the professionals involved. 

By utilizing wavefront sensing technology, the company reduces the time needed to ensure the quality of the materials it uses, alongside the number of faulty products that leave the production line, and expands the knowledge of the inspectors in the field of optics. 

 

 

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