top of page
OptiScan: Your Co-Pilot in Predictive Manufacturing
An AI-driven platform for predictive quality control and defect prevention across all manufacturing processes.
OptiScan ensures flawless parts every time – from advanced 3D printing to traditional machining and beyond.
Widget Didn’t Load
Check your internet and refresh this page.
If that doesn’t work, contact us.
Our AI interprets machine data, catching risks early and guiding teams to fix them before parts ever leave the floor
Key Features Capabilities Modular Architecture
A powerful machine learning core that predicts defects before production. It uses design/process simulations and past data to identify risk zones (e.g. distortion-prone geometries or areas likely to overheat) in any given part and process. This engine is continuously learning, getting smarter with every part produced.
A connectivity module that plugs into your machines – from industrial 3D printers to CNC mills, welders, and more. It streams live sensor data (thermal images, acoustic signals, pressure readings, etc.) and feeds it to the AI. Crucially, it also sends instant insights to the operators to prevent defects in-flight. This process works on the microsecond scale, so issues are addressed the moment they’re detected.
Intelligent algorithms that dynamically adjust toolpaths and process parameters. OptiScan doesn’t just set static “recipes” – it adapts. For additive processes, it optimizes scan paths and exposure to ensure even heat distribution (preventing residual stress and warping). In CNC machining, it can modify cutting strategies to minimize tool wear and part distortion. In casting or molding, it could regulate cooling rates to avoid material stresses. This adaptive layer is modular for each process type but unified under one platform, guaranteeing optimal process conditions whatever the manufacturing method.
A comprehensive database of material behaviors and process physics. OptiScan comes pre-loaded with insights from metallurgy, plastics, and composites, as well as models for processes like laser melting, milling, and beyond. This knowledge base helps the AI make context-aware decisions – for example, knowing how a particular alloy will respond to a heat spike, or how a certain polymer might warp if cooled too quickly. Manufacturers can also extend this library with their own proprietary process data.
An (optional) community-driven feature where OptiScan learns from every user’s experience. When enabled, data from diverse production environments (different industries, machines, materials) feeds into aggregate AI model improvements. That means the more companies use OptiScan, the smarter it becomes for everyone – all without compromising any individual’s IP or sensitive information. This network effect keeps OptiScan at the cutting edge of defect prevention techniques across the manufacturing world.
A unified interface that turns complex data into actionable insights. Engineers and operators get real-time dashboards showing process health (temperatures, stresses, etc.) and clear indicators when OptiScan intervenes to prevent an issue. The system provides actionable alerts and recommendations – for instance, suggesting a design tweak if it repeatedly had to slow down a certain toolpath. The dashboard can be customized per industry (e.g. showing relevant metrics for aerospace powder-bed fusion vs. CNC drilling) but maintains a consistent, easy-to-understand layout. This means your team always has visibility and confidence in the process, with AI-driven guidance at their fingertips.
Widget Didn’t Load
Check your internet and refresh this page.
If that doesn’t work, contact us.
Industry Applications Case Studies
High stakes, high standards. Aerospace manufacturers are among OptiScan’s first adopters, using it to produce flight-critical components with unparalleled reliability. In metal additive manufacturing for aerospace, scrap rates can reach 15–25% per build – a huge waste in time and cost. OptiScan has demonstrated it can slash these failure rates, catching issues like residual stress hot-spots before a build fails. For example, a rocket engine part that normally might crack during 3D printing can be produced first-time-right with OptiScan’s thermal control adjustments. Beyond printing, aerospace CNC machining lines benefit too: OptiScan can monitor tool wear and vibration when milling precision parts (like turbine blades), preventing costly tool breaks or part defects. The result is zero-defect components that meet strict aerospace certifications faster.
Precision and trust. In the medical field, consistency isn’t just about cost – it’s about patient safety. OptiScan is helping medical device manufacturers (for instance, those 3D printing orthopedic implants or precision-machining surgical tools) achieve 100% defect-free output. For a company printing custom implants, even microscopic porosity or distortion can mean a part is rejected and a surgery delayed. By using OptiScan’s in-situ monitoring, one manufacturer reduced implant build failures by such a margin that surgeons now receive parts faster with full confidence in their quality. The platform’s traceability is also key here: every implant comes with an automated quality report, making FDA approval and audits more streamlined.
Scaling quality in high-volume production. While not yet deployed at full scale in automotive plants, OptiScan’s technology is poised to add value in automotive and general industrial manufacturing. Think of an automotive factory stamping or machining thousands of parts a day – a small defect rate can translate into hundreds of faulty parts if unchecked. OptiScan can integrate with processes like casting, injection molding, and robotic welding on assembly lines to catch defects early (for example, porosity in cast engine blocks or weld integrity issues in car frames). By predicting distortion or monitoring equipment health (like press tonnage or robot arm alignment) in real time, it can help keep mass production on track with minimal scrap. The same goes for general industrial equipment manufacturing: OptiScan’s adaptive control would let factories fine-tune operations continuously, reducing downtime and ensuring that even large-scale runs yield uniform, high-quality output.
Quality assurance for infrastructure-scale projects. In energy and heavy industries (like power generation, oil & gas equipment, heavy machinery), manufacturing processes deal with massive parts and extreme conditions. These sectors could benefit greatly from OptiScan’s AI oversight. For example, consider the production of a wind turbine gear or a pressure vessel: flaws in such large components can be catastrophic or extremely costly. OptiScan could monitor a complex welding process on a pressure pipe, adjusting parameters to avoid cracks that might lead to leaks. In casting large turbine blades, the AI could manage cooling to prevent internal voids. Industrial energy systems often involve custom, one-off builds (huge castings or forgings); OptiScan would ensure those expensive single-run parts come out right on the first try. Although our current case studies are in aerospace/medical, the same principles apply here – and we’re actively exploring pilot projects in these heavy industries to prove it.
Widget Didn’t Load
Check your internet and refresh this page.
If that doesn’t work, contact us.
Frequently Asked Questions
OptiFab delivers advanced production recipes, real-time monitoring, and near-real-time control of manufacturing processes. We also ensure precise machine movement (toolpaths) for optimal results, minimizing defects and maximizing efficiency.
Our technology eliminates the need for costly post-processing steps like heat treatment and HIPing. By ensuring the part is fully uniform during production, OptiFab saves both time and money while delivering high-quality, ready-to-use components.
With our real-time monitoring and near-real-time control, the need for testing and inspection is almost entirely eliminated. Errors are detected and corrected during production, leading to defect-free parts and minimizing the need for post-production checks.
Industries such as aerospace, automotive, and medical benefit significantly from OptiFab’s solutions. In these sectors, where high-quality, defect-free parts are critical and production efficiency is paramount, OptiFab helps deliver superior results.
OptiFab controls machine movement through precise toolpaths, optimizing the manufacturing process in real-time. This ensures that each part is produced to exact specifications with minimal variation, reducing the need for rework and post-processing.
Absolutely. Our software is highly customizable, adapting to your specific production environment, materials, and goals. Whether you need tailored porosity levels, surface roughness, or other adjustments, OptiFab ensures the best possible outcome for your operations.
Real-time monitoring detects potential issues instantly, while near-real-time control allows our system to adjust parameters on the fly. This prevents defects from occurring, ensuring continuous, high-quality output with reduced downtime and minimal errors.
By eliminating post-processing steps such as heat treatment and HIPing, and reducing the need for testing and inspection, OptiFab can save manufacturers significant costs and time, often up to 20% or more, depending on your production setup and scale.
bottom of page