OptiZ: Robotic inspection and 3D defect mapping for complex devices

Complex devices are the slowest and least consistent to grade by hand. In one customer deployment, fifteen operators inspected headphones one at a time under a light, searching for micro scratches, dust, and small marks. Results varied from operator to operator, and inspection became the bottleneck for the entire repair flow. OptiZ automated the inspection, increasing throughput and delivering consistent quality on every device.

Each surface of a complex device presents its own inspection challenge. Curved lenses, internal and external cameras, seams, and coatings can conceal defects that go unnoticed until the device reaches the next customer, and two inspectors can look at the same lens and disagree. Manual inspection of complex devices realistically delivers:

• Large operator teams just to keep inspection moving
• High variation from operator to operator
• Throughput that limits the rest of the repair flow
• Disputes between grading and rework over what actually needs fixing

With OptiZ, every device follows the same robot path under the same light, and each defect is pinned to a 3D model before anyone picks up a tool.

• Robotic camera paths The robot moves the cameras through a defined sequence and repeats the exact path for every device, reaching angles operators can’t see.
• Precision lighting A controlled light dome lights each surface in a precise pattern, so defects hidden by lenses and coatings show up consistently.
• A 3D defect map OptiZ builds a 3D model of every device and marks each area that needs attention. Operators rotate it on a touch display and go straight to the fix, with fewer disputes between grading and rework.
• One platform for new device families The robot path adjusts to new shapes, grading logic updates per commodity, and adaptive grippers handle devices warped from use. The grading model is trained across headphones, laptops, glasses, and consumer devices, so new programs ramp faster.
• A clean cabinet Positive air pressure keeps dust out, so every mark the cameras find is a real defect.
• Data for parts planning Grading data shows which parts wear out most often, improving forecasts and reducing last-minute procurement.