Custom AI Vision Services
Bespoke computer vision systems engineered around your unique production challenges. From design to deployment — we build solutions that work for the problems off-the-shelf systems can’t solve.
±0.1mm
Dimensional Accuracy
<1 day
From POC to Deployment
99%+
Detection Accuracy
100%
Inline Coverage
When Off-the-Shelf Isn’t Enough
Standard AI quality control systems handle common defects well — surface scratches, component presence, label inspection. When your situation falls outside that range — unusual materials, complex 3D geometry, tight tolerances, robot integration, regulated environments — a custom system is not a luxury. It’s the difference between a solution that works and one that doesn’t.
Why Custom AI Services Exist
Your production challenge is unique. Your materials, geometry, tolerances, environment, and workflow are different from everyone else’s. A system built for generic cases won’t capture what matters in your specific situation. Custom AI services start with your challenge, not a product catalog.
Typical Custom Project Triggers
- Reflective or transparent parts: Glass, metal, foil, clear plastic require specific lighting and optics
- Complex 3D geometry: Parts that need depth, curvature, height deviation detection
- Tight system integration: Robot guidance, PLC triggering, MES connectivity, real-time feedback loops
- Regulated industries: Pharma, aerospace, automotive suppliers needing specific traceability and audit trails
- Multi-stage inspection: Across an entire cell or production area, not just a single station
- Non-standard defects: Defects that aren’t visually obvious or require domain expertise to recognize
Our Custom AI Services
Six core service areas covering the full spectrum of bespoke vision system needs.
🧠Custom AI Model Development
Models trained on your specific parts, defect types, and quality standards — not generic datasets. Multi-class defect classification, anomaly detection, and predictive quality with tolerances you define.
🔧Hardware Selection & Integration
Camera selection, lighting design (structured, diffuse, coaxial, UV), optics, triggering, mechanical mounting — we specify and source every component for your environment and cycle time.
📐3D Reconstruction & Measurement
Surface mapping, dimensional verification, and volumetric defect detection using structured light and stereo vision. For parts where 2D inspection can’t capture what matters.
🤖Robot Vision Guidance
Vision-guided robot systems for pick-and-place, bin picking, welding path correction, and precision assembly. Real-time pose estimation enabling flexible automation.
🥽Augmented Reality Integration
AR-guided work instructions that overlay directly onto the operator’s field of view — reducing assembly errors in complex workflows without disrupting existing line layout.
📡Anomaly Detection & Predictive Maintenance
AI models that learn your machine’s normal visual and vibration signature, then flag deviations before they become failures. Reduce unplanned downtime.
Vertical Solution Areas
These are the specific manufacturing verticals where we most often deploy custom AI vision systems.
Transform Videos into Technical Manuals & SOPs
Capture expert assembly workflows on video, then automatically transform them into step-by-step work instructions. AI extracts sequence, identifies critical steps, and generates SOP documentation for training and compliance.
Workflow Automation & Intelligent Routing
Vision-based production decision-making: route parts to different lines based on defect detection, complexity, or customer requirements. Real-time workflow orchestration without human intervention.
Maximize OEE with Computer Vision
OEE (Overall Equipment Effectiveness) optimization through real-time availability, performance, and quality monitoring. Vision systems track downtime, identify bottlenecks, and predict failures before they happen.
Wearable Injector & Cartridge QC
GMP-compliant quality control for pharmaceutical wearable injectors and cartridges. Inspects fill level, assembly integrity, labeling, and packaging at production speed.
Safety at Sea
Maritime safety monitoring using AI vision: detect objects in water, monitor crew, track cargo integrity. Real-time alerting for maritime operators and fleet management systems.
Seed Quality Control
Automated seed grading and quality verification. AI classifies seeds by size, shape, color, and viability. High-speed sorting and traceability for agricultural operations.
Your Custom AI Implementation Path
From first conversation to live deployment — typically 2 to 6 weeks depending on complexity.
Free Assessment
We visit your line or review video/photos to understand the inspection challenge, cycle time, and constraints.
System Design
We propose specific hardware and software architecture — camera, lighting, model approach — with clear cost and timeline.
Proof of Concept
We train the model on your actual parts and run the system at your station. You see real detection numbers before any commitment.
Integration
Connection to your PLC, MES, ERP, or SCADA. Pass/fail output, data logging, and dashboard access configured to your requirements.
Live & Supported
Deployment, operator training, and ongoing model updates as your product variants evolve. We stay involved.
Custom AI ROI & Value
Custom projects show measurable ROI faster than you’d expect. Here’s why.
Typical Value Drivers
💰 Reduced Rework & Scrap
Catching defects at the line instead of downstream saves 5-10x per defect. A custom system tuned to your specific defects eliminates rework entirely.
⚡ Faster Throughput
Inspection bottlenecks disappear when AI works at production speed. Lines often run 15-25% faster with zero manual inspection time.
👥 Labor Reallocation
Inspectors and supervisors freed from repetitive checking. Redeploy to quality engineering, process improvement, and customer support.
📊 Real-Time Visibility
100% data capture enables root cause analysis, trend tracking, and predictive quality improvements. Better decisions = fewer problems.
Sample ROI Timeline
Month 1-2: System deployed, data collection begins. Early defect reduction visible. Rework costs dropping.
Month 3: Full ROI realized. Payback period typically 8-14 weeks depending on defect volumes and rework costs.
Year 1+: Ongoing value from data insights, model improvements, and operational visibility. System typically pays for itself many times over.
Real-World Custom AI Deployment
Custom 3D Vision System for Precision Welding Inspection
Challenge: Complex automotive component with critical welds. Tolerances ±0.2mm on depth and penetration. Manual inspection: 2 minutes per part, 60% miss rate. Customer threatening to move production.
Solution: Custom 3D structured light vision system designed specifically for weld seam geometry. AI model trained on 500+ weld samples (good and bad). Integration with weld robot for real-time feedback.
Results:
- Weld inspection: 2 min → 5 seconds (−75% cycle time)
- Detection accuracy: 60% → 99.2%
- Rework rate: 8% → 0.3%
- Customer satisfaction: Restored to contract status
- Annual savings: €380k (rework reduction + throughput)
- ROI payback: 6 weeks
Custom vs. Off-the-Shelf Systems
When should you choose custom? When off-the-shelf can’t solve your specific problem.
Choose Off-the-Shelf When:
- Your defects are common and visually obvious (scratches, presence, size)
- Your parts are flat, regular geometry
- Your tolerance stack is standard (±0.5mm or worse)
- You have simple PLC integration needs
Choose Custom When:
- Your parts are reflective, transparent, textured, or unusual material
- You need tight tolerance verification (±0.1mm or better)
- Your defects are subtle or domain-specific (requires expert training)
- You need 3D geometry inspection or robot guidance
- Existing systems have been tried and failed
- Your customer or regulator requires proven, auditable traceability
Ready to Deploy a Custom AI Vision System?
Schedule a free assessment of your specific production challenge. We’ll analyze your defects, constraints, and requirements, then show you the exact system architecture and timeline we’d recommend.
Book Your Free Assessment →