ZEISS Automated Defect Detection (ZADD)
Artificial intelligence (AI) in computed tomography (CT)
Reliable evaluation software for inline and atline X-ray inspection
The ZEISS Automated Defect Detection (ZADD) software detects even small and fuzzy defects in components reliably and quickly. The Automated Defect Detection (ADD) software, also called Automated Defect Recognition (ADR) software, can be used not only for injection molded parts, but also for batteries and medical or additively manufactured components.
ZEISS offers everything from a single source: with the complete ZEISS X-ray portfolio, you can use artificial intelligence (AI) in 3D computed tomography (CT) and 2D X-ray technology both inline and atline. ZEISS Automated Defect Detection (ZADD) software is compatible with all ZEISS computed tomography systems.
Your advantages with the ZEISS Automated Defect Detection software at a glance

Defect analysis in only 60 seconds in inline mode
- Minimization of test cycle times
- Faster scans/defect detection
- Time savings for operators

Robust quality results & clear reporting
- Perfect results, even if image quality is not perfect
- Suitable for mixed and dense materials

No parameter tuning required
- Subjective decisions are avoided
- No reference data required in atline mode

User-defined ZEISS Automated Defect Detection software
- Custom optimization of defect analysis
- User-defined programming of the software
ZEISS Automated Defect Detection
AI software for your application areasZEISS Automated Defect Detection machine learning software sets new standards by applying AI to 3D CT and 2D X-ray systems with CT option. It detects, localizes and classifies defects or anomalies (irregularities) while analyzing them in detail by reading CT-scans and X-rays. Based on inspection regions, the AI software evaluates whether the defect will pose a problem after further processing steps and whether the component must be rejected as a result. If similar defects occur more frequently in inline operation, this can be detected and thus intervention in the production process can take place at an early stage to reduce scrap and save costs. In atline operation, the ZADD software is convincing in optimizing and monitoring the casting process as well as improved and faster component development.

Reliably detect defects in components
During the complex manufacturing process of components, different defects can occur. Especially inside the part, defects are invisible to the naked eye and can have a major impact on the stability and functionality of the component. Artificial intelligence combined with industrial computed tomography or 2D X-ray technology makes these hidden problem areas visible, analyzes them and detects them at an early stage. The ZEISS Automated Defect Detection software specializes in the detection of different defects, so that defects can be detected quickly and reliably even in poor image quality with many artifacts.
Inline defect analysis in just 60 seconds
In order to be able to sort out defective components at an early stage in a value chain, the 3D data must be evaluated reliably and quickly during an inline inspection. In just 60 seconds, the ZEISS Automated Defect Detection analysis software reliably examines 4 billion voxels (3D pixels) for defects that are only a few voxels in size. Components with critical defects are thus accurately sorted out or, if possible, subjected to rework. Good parts, on the other hand, pass through the further machining process unhindered. The result: a lower reject rate and high component quality. In this way, you achieve a constant increase in efficiency and maximum process reliability with AI in CT.


Reliable evaluation
If the ZEISS ADD software detects a defect, the software evaluates it in terms of position, shape, size and type. For example, if pores are close to a surface that will be machined in the further process, they may pose a greater risk than elsewhere inside the component. The software is able to predict whether the defect may cause problems in subsequent machining steps. The component is then automatically rejected at an early stage. This saves you time and money. In addition, you can define in the ZADD software under which criteria a defect still meets the quality standards and when it is classified as critical. With ZEISS Automated Defect Detection, you get a solution that is tailored precisely to your requirements.
Clear reporting
If the ZEISS Automated Defect Detection software finds a critical defect in inline operation, it creates a report using the ZEISS PiWeb data management software. This gives you the opportunity to view and evaluate defects again afterwards in a 3D view. If your manual inspection leads you to the conclusion that the defect was caused by sand residue, for example, you can easily remove this source of defect and avoid unnecessary scrap. This results in high cost savings. The software also enables results to be displayed in tabular form and output in common formats such as csv.

Typical defects on and in components
ZEISS Inline X-Ray Systems with Automated Defect Detection
ZEISS Automated Defect Detection is compatible with any ZEISS computed tomography system and can be easily integrated into your process. During continuous inline measurement along the entire process, ZADD delivers precise results and detects the smallest defects or flaws early on.
ZEISS also offers a complete solution from a single source: with the ZEISS VoluMax inline X-ray system, you have the option of using AI for reading 3D CT scans with perfectly coordinated measurement technology and software.

ZEISS VoluMax
- Fully automated, non-destructive inline inspection
- Fast inspection of many workpieces in 3D
- Individual configuration depending on measurement task by ZEISS
- Choice of manual or automatic loading
- With Golden Part Inspection
ZEISS Atline X-Ray Systems with Automated Defect Detection
Atline measurements also benefit from AI in CT. Complex measurement procedures can be performed in the quality lab without the environment of production influencing the results. The ZEISS Automated Defect Detection software makes manual measurements more precise and detects defects in production quickly and accurately. In combination with ZEISS atline X-ray systems and GOM Volume Inspect Pro, you can achieve compliance with high inspection standards and efficient quality control.

ZEISS METROTOM
- Complex measurements and inspections
- Linear guides and rotary table
- Metrological traceability
- Small footprint with the ZEISS METROTOM 1
- Comprehensive computed tomography data analysis in 3D with GOM Volume Inspect Pro

ZEISS BOSELLO
- Industrial 2D X-ray inspection
- Optimal for high volume production
- High throughput
- Flexible application in many industries
- Atline CT option expandable with AI reading X-rays
Extensive service offer for ZEISS Automated Defect Detection users

Support
The ZEISS team accompanies you from the very beginning! You will receive support in the design and programming of the algorithm, so that your ZEISS X-ray system in combination with the ZEISS Automated Defect Detection software will contribute to process reliability and increased efficiency.

Custom
ZEISS caters to your application areas and needs! The AI-driven ZEISS Automated Defect Detection software can be trained with an individual model to become a customized solution for your measurement task.
Artificial Intelligence in X-Ray Technology
AI drives CT forward
Artificial intelligence is ubiquitous. Autonomous driving is just one of many examples of the application of AI. Artificial intelligence is also a topic in industry and thus in computed tomography and is becoming increasingly significant. This is because it enables defect analyses to be carried out even more reliably, accurately and quickly. In industry, a defect is often located inside a component. An optical inspection process for quality control is then no longer sufficient because it does not provide any indication of internal defects. X-ray inspection allows a close look inside a component and can thus detect defects at an early stage. By using AI in 3D CT and 2D X-ray inspection, a partially automated defect analysis is realized.
Explanation of terms:
In connection with AI and CT, the terms AI Defect Detection or AI Anomaly Detection are often used. AI stands for Artificial Intelligence and Defect Detection or Anomaly Detection means defect detection or anomaly detection. The addition of "NDT" makes it clear that AI works non-destructively, because NDT stands for non-destructive testing.
Workflow
How the ZEISS Automated Defect Detection software worksThe ZADD software has several features that you can use optimally in either your inline or atline process. In the slider, the features and for which solution they are suitable are explained in detail.
When will AI be used in CT?
Artificial intelligence is a trend in automation. Process requirements are becoming tighter and tighter, and even in harsh measurement environments, image evaluation and defect analysis must work quickly and reliably. This is especially true for safety-relevant components, e.g. in the automotive industry or aerospace. To increase quality by performing defect analyses faster, while at the same time offering high process reliability, AI is used for reading CT-scans. Defect detection with AI eliminates the need for manual tuning of parameters, thus avoiding subjective decisions in defect detection.
ZEISS Automated Defect Detection is particularly useful when volume data is affected by overly dense materials or short scan times. While artifacts and noise in the images usually cause faulty detections, the software remains unaffected by these effects.
Take a look at specific examples of how AI is used in 3D CT, but also in X-ray inspection in general:
These industries benefit from AI with ZEISS Automated Defect Detection
Would you like to learn more about ZEISS Automated Defect Detection?
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