Optical scan for subsurface defect detection

C. Harmer
Materic LLC, Maryland, United States

Poster stand number: T101

Keywords: defect detection, coatings, 3D rendering, characterization

Paint and coating defects in industrially manufactured vehicles are exceedingly common, but existing methods for dealing with them can cause major production bottlenecks, profit losses, and limit vehicle lifetime and durability. Automotive paint is typically applied in four layers: electrophoretic coat, primer, basecoat, and clearcoat; and each paint layer can have multiple sublayers (e.g. three layers of primer). Defects are caused by a variety of factors, including paint sprayer malfunctions, microbubbles or cracks in a layer, or foreign bodies (fibers, particulate matter, paint chips, etc.) caught in a layer. These defects can cause problems beyond just ruining the aesthetics of a vehicle. For example, chipping auto paint could lead to rust, which can shorten the useful lifespan of the vehicle. Perphora’s device will scan a defect in under 10 seconds, rapidly creates a 3D rendering with depth data, and automatically characterize the defect. This will allow manufacturers to quickly determine the source of a defect and fix it, without disrupting production workflows. Later versions of our system will also recommend specific corrective actions, creating a seamless automated process for identifying, characterizing, and fixing coating defects.