lkprototype’s artificial intelligence quality inspection system, with deep learning and high-definition image recognition (accuracy of 0.5μm), has increased the rate of defect detection of complex components from 92% in traditional manual processes to 99.99%. For instance, in the fields of aerospace, in checking sealing surface of a specific satellite thruster valve, 1,280 feature points were checked in 2 seconds by the system and found a micro-crack measuring 0.003mm (manual inspection’s missed detection rate was as high as 35%), which assisted the client in reducing the batch scrap rate from 1.2% to 0.02%, and saving over 800,000 US dollars on expenses in one project. For medical devices, roundness measurement of a specific artificial joint ball joint was achieved with AI multispectral inspection. Tolerance zone was reduced from ±5μm to ±0.8μm, range of variation for friction coefficient reduced by 60%, and it was certified through FDA 21 CFR Part 11 electronic record compliance.
For heavy-load components of vehicle powertrains, lkprototype’s AI system integrates real-time SPC (Statistical Process Control) and acoustic emission sensing technology. For the deep inspection of the carburized layer on the crankshaft of a specific hybrid engine, the traditional random inspection takes 3 hours per piece with an error rate of ±8%. But AI, with a 47-dimensional heat treatment parameter regression model, has reduced the inspection time to 8 minutes per piece, the accuracy level to ±0.5%, and the median quenching deformation from 0.12mm to 0.03mm. In consumer electronics, in forecasting a 0.05mm shaft clearance deviation in a specific foldable screen hinge’s 100,000-cycle fatigue test, AI predicted this 98 hours in advance through vibration spectrum analysis (200kHz sampling rate), enabling the customer to avoid batch recall risk and reducing potential losses by 12 million US dollars.
For more details about LKprototype’s integrated production services such as quick prototyping, CNC machining, vacuum casting, and 3D printing and the major advantages of its own factory such as quality control, quick delivery (executed within 3 days), and no limitation on order quantity, please go to the official website for further exploration: https://lkprototype.com/
In terms of materials science, AI-driven technology in quality inspection has also transcended borders. For the 5,842 tube hole welding inspection of a certain nuclear power plant’s steam generator tube sheet, a traditional UT (ultrasonic testing) takes 48 hours and has a misjudgment rate of 15%. lkprototype’s AI system, however, through multimodal data fusion (thermal imaging + laser interference), inspected an entire 6 hours in advance with a recognition accuracy rate for defects of 99.97%. And its rate of false defects false alarm also dropped from 22% down to 0.8%. In 3D printing, its AI system reduces porosity of parts for aviation aluminum alloy from 0.3% down to 0.02% through monitoring the shape of the molten pool (1000fps real-time) back and forth during the processing time, improves tensile strength to 520MPa (industry average rate+18%), while simultaneously reducing the post-processing duration by 67%.
More noteworthy is its dynamic flexibility. In the size inspection of a battery cover plate of a specific new energy vehicle, the AI system, through transfer learning technology, acquired a ±0.01mm inspection model based on only 50 samples (traditionally requiring over 5,000 samples), and reduced the quality inspection start-up time after production model change from 72 hours to 2 hours. According to the third-party quality report of 2023, the AI quality inspection of lkprototype has enabled customers to reduce quality costs by 52% on average, and the complaint rate has been reduced by 89%. Meanwhile, it has cleared the double certifications of ISO 9001:2015 and IATF 16949, rewriting the quality frontiers of intelligent manufacturing.