Rapid 3D inspection for plastics manufacturing

The Sentinel Vision 3D LaserScan solution enables 100% in-line inspection and faster defect detection powered by Zebra AltiZ Series High-Fidelity 3D Profile Sensors and Sentinel’s VisionCore software.

Plastic injection-moulded parts are used in everything from automotive and electronics to healthcare, but ensuring these parts are consistently free of defects and imperfections has remained a challenge.

Because of the moulding’s low-contrast surfaces, complex geometries, and translucency, traditional inspection methods have struggled to deliver both accuracy and scalability, often resulting in costly rework and waste.

“Manufacturers need inspection solutions that are both adaptable and precise,” said Joel Alves, chief commercial officer, Sentinel Vision. “With Zebra’s AltiZ sensors and our VisionCore platform, we’re helping customers achieve full inspection coverage and actionable insights, all with minimal disruption and rapid deployment. Return on investment is typically achieved in under six months.”

Sentinel, working closely with Zebra and Clearview, a Zebra Industrial Automation Distributor, has developed a solution that addresses these challenges. The 3D LaserScan solution uses Zebra’s AltiZ dual-camera and single-laser profile sensors to minimise scanning gaps on critical surfaces, ensuring even the most complex moulded parts are thoroughly inspected.

Combined with VisionCore software, which fuses 2D and 3D image processing for real-time analysis, the solution empowers manufacturers to inspect every component immediately after moulding—without slowing down production lines.

“The modularity and compatibility of Zebra’s technology, paired with Sentinel’s innovative software, means manufacturers can integrate advanced inspection capabilities quickly and confidently,” said Andrés Carrillo Serrano, director, Clearview. “This partnership is redefining what’s possible for quality control in plastics manufacturing.”

The 3D LaserScan system, designed for easy integration, enables connected frontline operations and real-time asset visibility. With deployment taking less than an hour and intuitive touchscreen controls, manufacturers benefit from reduced scrap, fewer warranty claims, and a solution that scales across a range of industries and production environments.

“Zebra’s relentless commitment to an open ecosystem and customer-focused innovation continues to enable intelligent operations across the manufacturing sector,” said Luca Gallo, machine vision manager, Southern Europe, Zebra Technologies. “This solution empowers connected frontline workers and drives intelligent automation, delivering actionable insights and greater process consistency for our customers.”

www.zebra.com