Hidden risk revealed with advanced computed tomography
Published Tuesday October 21, 2025When performance, safety, and trust are on the line, small defects can lead to big problems. For one leading MedTech manufacturer, a hidden assembly issue had the potential to cause field failures, product recalls, and damage to their brand. The company turned to Kinetic Vision to verify product integrity using advanced computed tomography (CT) scanning, expecting to find only minor deviations. What we discovered told a very different story.
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The client’s assemblies incorporated flexible components enclosed in sterile, foil-based packaging, preventing internal inspection with conventional methods. Visual checks and manual sampling failed to capture subtle geometric variations responsible for inconsistent product performance. Although the client estimated a 3% defect rate, hidden internal features made it impossible to verify the actual scope of the problem.
Our approach and findings
To address this challenge, our metrology team developed an automated CT scanning and analytics workflow capable of evaluating thousands of units without opening a single package.
By combining voxel-based modeling, CAD alignment, and Python automation, 3D scan data was converted into precise digital models and measured across hundreds of cross-sections. This process produced a comprehensive dimensional profile for each component, allowing accurate classification of good, marginal, and failed parts.
The findings showed a much higher defect rate than expected. Instead of the projected 3 percent, more than 70 percent of assemblies fell outside tolerance limits. This insight enabled the client to pinpoint manufacturing issues, take corrective action, and prevent potential failures in the field.
The benefits of computed tomography
Computed tomography offers a level of insight that traditional measurement tools can’t match:
- Non-destructive inspection – View internal and external geometries without disassembly or damage.
- Full 3D visualization – Capture complex shapes and assemblies in true spatial context.
- High measurement accuracy – Quantify internal dimensions with micron-level precision.
- Automation scalability – Integrate with data pipelines for high-volume analysis.
- Root cause analysis – Identify geometric or material inconsistencies invisible to surface scans.
Computed tomography has become a cornerstone for validating products and components across all industries. Kinetic Vision helps organizations apply this technology to uncover hidden risks, ensure quality, and improve product performance. Ready to explore how our team can help you with your next project? Visit our contact page today to get started.
Legal Disclaimer: The product depicted is for illustrative purposes only and does not represent the actual component analyzed.
