Hand-held defect detection

  • Defect detection in the μm range
  • Replaces cumbersome molds
  • Direct measurement in the production area, for incoming goods inspection and outdoors
  • Developed for defects in aircraft parts
  • Handheld, workstation or robotic operation

Contact person: Michael Zerbin


4D Technologies Handheld System InSpec meets the ravages of time! This was developed for the user to directly measure defects, radii and angles. The InSpec can be used to measure directly on the surface of the parts to be tested.

The system originally developed for aviation can also be used for any other application. The advantage compared to other systems is that it can be used anywhere inside and outside the plant. The device is mobile like a tablet and with an accuracy that can be compared to microscopes.

Easy-to-use software evaluates the surface structure, identifies defects and measures them precisely. Various reports can be created in a simple manner or data can be transferred to quality control systems for pass/fail analysis.

The sensor can also be guided automatically by a robot over the surfaces to be examined and record measurement data in the process.

InSpec XL

The InSpec XL is the large variant of the InSpec. With the XL, a larger area can be measured, but with small compromises in resolution.


InSpec InSpec XL
Measurement field size: 7.7 mm x 7.7 mm Measurement field size: 15mm x 15mm
Spacing: 35mm Spacing: 54mm
Light source: 450nm LED LED Light source: 450nm
Dimensions: 280mm x 50mm x 70mm Dimensions: 260mm x 150mm x 45mm
Sensor: 1200 pixels x 1200 pixels; 12-bit Sensor: 2048 pixels x 2048 pixels; 12-bit
Weight: 0.9 kg Weight: 1.4 kg
Robot suitability: YES Robot suitability: YES
Cable length: 10m Cable length: 10m
Mobile version: YES Mobile version: YES


  • Determine defects, radii and angles on turbine blades
  • Fire cracks on engine blocks
  • Defect detection in gaps in truck diaphragm springs
  • Defect detection on brake blocks
  • Display of leather textures
  • Scratches and cracks on transmission parts
  • sink marks on plastic parts
  • Measurement of undercuts using mirrors

measuring ranges

Defect sizes: 5µm -2.5mm Defect sizes: 7µm -9mm
Min. roughness: 120nm (6µm) Min. roughness: 120nm (6µm)
Measurement time: <1sec. Measurement time: <1sec.
Max step height: 180µm Max step height: 340µm


  • Handheld, workstation, or robotic operation
  • portable mobile kit (battery, tablet and case)
  • mobile kit (laptop, battery, stand)
  • Flexible arm for positioning
  • Mirror set in different designs
  • Calibration standards according to all international standards
  • mobile power supply

Video I

Video II

data sheet




4D Technology installs high-throughput, high-resolution automated edge break system at an aerospace engine manufacturer

4D Technologies, a wholly owned subsidiary of Onto Innovation Inc., has installed and commissioned a 4Di InSpec AT automated inspection system at a leading aerospace engine manufacturer. The system will move into full production next quarter.

“We developed the 4Di InSpec AT in collaboration with leading aerospace engine manufacturers to dramatically improve the measurement process,” said Erik Novak, Managing Director of 4D Technologies. “By improving measurement accuracy, the system significantly reduces rework and scrap caused by the rejection of actually good parts. Additionally, it improves inspection throughput by several orders of magnitude, saves critical labor, and provides rapid production feedback to improve part quality.”

Aircraft and engine components can have dozens of critical specifications for chamfers and curves to optimize performance and life. These numerous characteristics can only be measured manually, which is time-consuming. Areas that are difficult to access must be replicated for measurement, which further increases cycle time.

The 4Di InSpec AT system combines the industry-leading 4D InSpec surface measurement device with a collaborative robot for non-contact measurement of chipped edges, chamfers and fillets, as well as surface defects such as pits, scratches and dents on aerospace parts. With measurements taking only seconds, as opposed to many minutes or hours with manual methods, the automated system significantly increases measurement throughput and workload. The ability to measure features in difficult locations further improves inspection quality.

“The 4D InSpec surface measurement device has become established in the aerospace and MRO (rework/repair) industries,” said Novak. “The fact that leading manufacturers are now using this technology in inline production underlines its great value to the industry.”

Highlights of the 4Di InSpec AT include:

  • Measure dozens of edge break features, chamfers, radii and defects in minutes instead of days.
  • Non-contact 3D measurement with a resolution in the micrometer range.
  • Patented vibration-insensitive technology enables measurements in the workshop.
  • Specially developed software flags measurements that are out of specification and automatically remeasures the locations.
  • Integration with Fanuc CRX 5iA or CRX10iA/L collaborative robots.
  • Ability to measure inner and outer wave characteristics using folding mirrors and compact probe design.
  • Optional rotary table for improved throughput.
  • Numerous safety features including a fully enclosed cell.

Link to article


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