Industry

Inspection Method

Semiconductor

Visual Inspection

7 Best Visual Inspection Systems (2024)

Averroes

May 22, 2024

Survival and growth in the competitive world of manufacturing & production often fall to fractional improvements in efficiency.

Visual inspection systems are key applications for such efficiency improvements. With an endless number to choose from, it can often be hard to figure out which to explore as potential adoption options.

Hence, why we’ve created this list of the best visual inspection systems in 2024.

Discover how Averroes.ai, Mirtec, Orbotech, Camtek, Omron, Nordson, and Viscom are revolutionizing defect detection, quality control, and yield optimization in various industries and which ones would be best suited to your company’s needs.

7 Best Visual Inspection Systems of 2024

1. Averroes.ai

It might seem biased to put our own automated AI visual inspection system as the number one pick. However, Averroes.ai has capabilities no other visual inspection system offers and is highly regarded as being the easiest system to integrate into current operations.

Our innovative technology offers unparalleled defect detection, monitoring, classification, and segmentation capabilities, significantly enhancing quality control processes.

Its ability to seamlessly integrate with proprietary technology while being data-agnostic and requiring no coding is among the key reasons it is the leading choice.

Our system also enables semiconductor virtual metrology using the same equipment, offering comprehensive solutions for precision measurement and inspection needs.

Features and Benefits

Enhanced Defect Detection: Improves defect detection rates by 60% compared to traditional methods.
High Accuracy Rate: Over 99% accuracy in defect detection, ensuring unmatched reliability in defect detection, reducing the risk of faulty products reaching consumers.
Low False Rejects: Minimizes false rejects, ensuring that good products are not incorrectly discarded during inspection, thereby reducing unnecessary costs and production delays.
Increased Yield and Throughput: Up to 20% increase in yield and throughput.
Rapid AI Model Development: No-code AI model creation within hours, streamlining deployment and saving valuable time and resources.
WatchDog Anomaly Detection: Feature acts as an unsupervised model atop supervised ones, identifying unidentified defects beyond labeled ones. This enhances precision in defect identification.
Submicron & Nanometer Inspection: Detects defects at submicron and nanometer scales, vital for industries like semiconductor manufacturing where precision is paramount.
Versatility Across Industries: Applicable in various sectors, from semiconductors to pharma and solar farms.
Domain Expertise: Unlike most visual inspection equipment on the market, which requires domain expertise for calibration and programming due to their reliance on template matching or classical machine vision techniques, Averroes.ai eliminates this requirement by leveraging AI that can be trained on images.

Drawbacks

Infrastructure Requirements: Optimized for semi-automated production lines, meaning it requires pre-existing cameras and some automation already in place.

Rating

5/5: Averroes.ai excels in accuracy, defect detection, and versatility, making it a top choice for advanced manufacturing inspection needs.

2. Mirtec

Mirtec is a leading provider of advanced automated optical inspection (AOI) systems for the electronics manufacturing industry.

Their product lineup includes both desktop and inline AOI systems designed to enhance quality control processes through high-precision defect detection and comprehensive inspection capabilities.

Mirtec’s 3D AOI and SPI inspection systems are designed for compatibility and integrate seamlessly with existing hardware setups. This means you can integrate their systems with your current setup without completely overhauling new technology.

Features and Benefits

OMNI-VISION® 3D Inspection Technology: Utilizes digital tri-frequency Moiré technology to achieve superior 3D profiling of devices up to 25mm tall.
High-Resolution Cameras: Features CoaXPress Cameras (15MP or 25MP) for ultra-high resolution imaging.
Advanced Lighting Systems: Eight-phase color lighting system with high-intensity white and color LEDs for enhanced ROI illumination.
Z-Axis Inspection: Multi-focus programmable Z-axis system for inspecting tall components beyond the lens’s focal range.

Drawbacks

High Cost: Significant initial investment may be a barrier for smaller manufacturers or low-volume production environments.
Shadowing Issues: The Moiré fringe pattern projection technology can lead to shadowing effects where taller components obscure lower-lying devices, particularly in dense PCB layouts.

Rating

4.5/5: Mirtec’s visual inspection systems excel in technology and versatility, offering exceptional defect detection and comprehensive inspection solutions. However, their high cost and potential for shadowing issues may present challenges for some users.

3. Orbotech

Orbotech, part of KLA, specializes in advanced automated optical inspection (AOI) systems for manufacturing. Their solutions leverage AI and machine learning to optimize defect detection, yield, and production efficiency.

Orbotech’s systems are designed to integrate with existing hardware setups in PCB and IC substrate manufacturing environments and include advanced features that support a wide range of inspection and metrology applications.

Features and Benefits

Ultra Dimension Series:

Pattern Inspection: Detects minute defects in PCB patterns.
Laser Via Inspection: Ensures precision in laser-drilled vias.
RMIV Pro: Enhances reliability with advanced algorithms.

Ultra Fusion Series:

Multi-Image™ Technology: Provides high detection accuracy through multiple image captures, enhancing defect detection and process control.

Discovery II Series:

SIP™ Technology: High defect detection rates with minimal false alarms, ensuring reliable inspection and quality control.

Zeta™-6×0 Series:

Multi-Mode Metrology: Combines 3D and 2D metrology capabilities with panel inspection, offering comprehensive analysis and measurement.

Drawbacks

False Reject Rate: While their systems aim to reduce false rejects, the complexity of handling large volumes at high resolutions still presents challenges in ensuring accuracy without unnecessary rejections or false positives.

Rating

4.5/5: Orbotech’s visual inspection systems excel in accuracy, integration, and yield optimization, but their high cost is a notable drawback.

4. Camtek

Camtek is a prominent manufacturer of metrology and inspection equipment, providing solutions tailored to the semiconductor industry.

Their focus spans Advanced Packaging, Memory, MEMS, CMOS Image Sensors, and RF segments. Camtek’s systems are designed to enhance yield and ensure the quality of semiconductor components.

Features and Benefits

2D and 3D Metrology: Integrated on a single platform, allowing for comprehensive analysis.
Inner Crack Imaging (ICI): Detects side wall cracks in post-diced wafers, which are critical for the reliability of advanced packaging applications.
Multi-Level Software Alignment: Ensures precise alignment for reliable defect detection across various wafer sizes and types.
Sub-Micron Surface Defect Detection: Capable of detecting very small defects crucial for high-precision applications.

Drawbacks

Complex Setup and Operation: Camtek’s systems, such as the Eagleᵀ-i, while designed for high accuracy and speed, involve complex setup and operational procedures.
Maintenance Requirements: High-end equipment typically requires regular maintenance to operate efficiently, which can add to operational costs and downtime.

Rating

4/5: Camtek’s visual inspection systems are recognized for their precision, comprehensive solutions, and innovative technology. However, their complexity and maintenance demands potentially limit their usability in less resource-intensive environments.

5. Omron

Omron’s AI Visual Inspection System uses deep learning to detect defects in manufacturing, addressing the limitations of traditional systems.

The system is designed to adapt to diverse materials and shapes, offering high accuracy without requiring high-cost computing resources like GPUs.

Features and Benefits

Deep Learning Algorithms: Pre-trained models detect various defects without needing extensive setup or image collection.
CPU Optimization: High-speed processing without GPUs, reducing costs.
Feature Map Visualization: Highlights defect areas for easy identification.
Versatility: Adapts to different materials and defect types.

Drawbacks

Initial Setup Complexity: May require significant effort to build a comprehensive learning image database.
High Dependency on Pre-Training: Performance may vary with novel or unexpected defect types.

Rating

4/5: Omron’s system excels in adaptability and cost efficiency but may face challenges with initial setup and novel defect types.

Construction

Automated visual inspection in construction improves safety and durability by detecting and analyzing defects such as cracks, foundation settlements, rebar placement errors, water intrusion, and other construction flaws.

Early detection allows for timely corrective measures, which are crucial for the longevity and safety of buildings and infrastructure.

6. Nordson

Nordson is a global leader in precision technology solutions, providing advanced visual inspection systems primarily through its Nordson Test & Inspection division.

Nordson provides both hardware and software solutions as part of its product offerings. They manufacture a wide range of equipment, including systems for dispensing, measuring, controlling, and inspecting, among others, that are used across various industries.

Features and Benefits

Automated Optical Inspection (AOI): High-speed and high-resolution systems for defect detection.
X-ray Inspection Systems: Non-destructive inspection for internal defects and assembly verification.
Acoustic and Optical Metrology: Advanced systems for precise measurement and defect detection in materials.
Versatility: Suitable for a wide range of applications, including semiconductor, automotive, and medical devices.
Advanced Software: Intuitive interfaces with powerful analysis tools to enhance defect detection and process control.

Drawbacks

Complexity and Cost: Systems like the Quadra™ series come with high operational and maintenance costs.
Specialized Training Required: Systems such as the CyberOptics SQ3000™ may require specialized training, potentially increasing operational costs and reducing personnel flexibility.

Rating

3.5/5: Nordson’s visual inspection systems are highly sophisticated and versatile, suitable for a variety of industrial applications. However, their complexity and the high cost of ownership may pose challenges for some organizations, especially those with limited resources.

7. Viscom

Viscom is a leading provider of high-precision inspection systems for the electronics industry.

Their comprehensive range includes automated optical inspection (AOI), X-ray inspection (AXI), solder paste inspection (SPI), conformal coating inspection (CCI), and bond inspection systems. These solutions ensure high-quality production by detecting defects in solder joints, components, and assemblies.

Features and Benefits

Automated Optical Inspection: High-speed 2D, 2.5D, and 3D inspection for PCBs and components.
X-ray Inspection: Inline and manual systems for non-destructive internal inspection.
Solder Paste Inspection: Fast and precise inspection for solder paste application.
Conformal Coating Inspection: Ensures proper application of conformal coatings.
Bond Inspection: Optical and X-ray inspection for wire bonds.
Software Solutions: Intuitive interfaces and powerful analysis tools for enhanced defect detection and process control.

Drawbacks

System Size and Integration Challenges: Particularly the heavy-duty models are large and may require significant space within production lines. Integrating these systems into existing manufacturing processes could be challenging and may require adjustments or redesigns of production layouts.

Rating

3.5/5: Viscom’s inspection systems offer comprehensive, high-precision solutions with advanced features, though the system’s size, integration challenges, and overall complexity are drawbacks.

Comparison Table

Features	Averroes.ai	Mirtec	Orbotech	Camtek	Omron	Nordson	Viscom
Complex Pattern Recognition	✔️	❌	❌	❌	❌	❌	❌
Low False Rejects	✔️ (Near Zero)	✔️	❌	❌	❌	❌	❌
Active Learning	✔️	n/a	n/a	n/a	n/a	n/a	n/a
Unknown Defect Detection	✔️ (WatchDog)	n/a	n/a	n/a	n/a	n/a	n/a
Multiple Model Processes	✔️	❌	❌	❌	❌	❌	❌
Domain Expertise	❌	✔️	✔️	✔️	✔️	✔️	✔️

Feature Definitions

Below are explanations of the key features listed in the comparison table, highlighting their impact on the effectiveness and efficiency of visual inspection in manufacturing settings.

Complex Pattern Recognition: Leverages AI to detect, classify, and segment complex defects in manufacturing processes.
Low False Rejects: Efficiently reduces the incorrect rejections of good products, saving unnecessary costs and avoiding production delays.
Active Learning: Continuously improves inspection algorithms with data feedback to adapt to changing manufacturing conditions.
Unknown Defects Detection: Detects new defects not previously programmed or encountered, ensuring quality in innovative products.
Multiple Model Processes: Runs various inspection models on a single machine, allowing customization according to quality assurance needs.
Domain Expertise: Specialized knowledge for specific industries, improving the effectiveness of inspection solutions.

Frequently Asked Questions

What industries benefit most from visual inspection systems?

The manufacturing industry benefits significantly from visual inspection systems due to their need for high precision and defect detection.

What is the role of AI in modern visual inspection systems?

AI in visual inspection systems enhances defect detection accuracy, reduces false positives, and allows for real-time data analysis. It enables the system to learn and adapt to new defects, improving without extensive reprogramming.

What are the cost considerations for implementing visual inspection systems?

Initial costs include purchasing the equipment, installation, and training. Operational costs involve maintenance, software updates, and potential upgrades. The ROI can be justified by reduced defect rates, improved product quality, and higher production efficiency.

What are the limitations of traditional visual inspection methods compared to AI-based systems?

Traditional methods rely heavily on human inspectors or simple machine vision techniques, which can be time-consuming and prone to errors. AI-based systems offer higher accuracy, consistency, and the ability to learn and adapt, reducing the need for manual intervention.

Conclusion

For organizations aiming to leverage their existing infrastructure, we’d suggest exploring our own system at Averroes.ai, as it integrates seamlessly, enabling enhancements without the burden of new installations. Our system supports current operations with minimal disruption and provides unmatched defect detection capabilities.

Conversely, for those looking to overhaul their systems and embrace a comprehensive suite of new technologies, Nordson provides robust solutions tailored to modern manufacturing demands. Its systems are designed to integrate with a new set of hardware, making it a good option for those prepared to invest in extensive upgrades.

If you’re looking to boost your production efficiency with seamless integration and advanced defect detection, request a demo from Averroes.ai today. See firsthand how our technology can meet your industry’s specific needs, driving significant efficiency and quality control improvements.