In this enlightening interview, we have the pleasure of speaking with Dr. Pradeep Bhattad, the Innovation Director at North Star Imaging (NSI). Headquartered in Rogers, Minnesota, NSI is renowned for its cutting-edge industrial X-ray imaging solutions tailored for quality inspection and research applications.
Dr. Bhattad brings nearly two decades of expertise in industrial X-ray imaging, a field he first delved into during his PhD in 2004. His journey through roles ranging from graduate student and application engineer to his current leadership position exemplifies a deep commitment to advancing non-destructive testing (NDT) technology.
In our conversation, Dr. Bhattad shares insights into the latest innovations and trends in industrial Digital X-ray and CT systems, the impact of NSI’s acquisition by Illinois Tool Works, and the challenges and triumphs encountered in developing state-of-the-art industrial imaging systems. His passion for pushing technological boundaries and his perspective on the evolving landscape of NDT offers a compelling glimpse into the future of industrial inspection technology.
Hello Dr. Pradeep Bhattad, Greetings of the day. Could you please introduce yourself to our wonderful audience?
Thanks OnestopNDT, I am Pradeep Bhattad, the Innovation Director at North Star Imaging, headquartered in Rogers, Minnesota. We specialize in industrial X-ray imaging for quality inspection and research applications. I got introduced to industrial X-ray imaging during my PhD in 2004, and since then I’ve been working with industrial X-ray imaging for nearly 20 years in various roles from graduate student, application engineer to now the innovation director with the NSI.
Dr. Pradeep, North Star Imaging has been a leader in advanced NDT technology. Can you share what innovations or trends you are most excited about in the field of industrial Digital X-ray and CT systems?
NSI has been a trendsetter in maximizing the capabilities of industrial X-ray systems, from achieving the highest image quality and flexibility of applications to breaking the barriers in terms of image resolution. Since the introduction of subpiX™, mosaiX™, and focal spot, NSI is unique in its ability to provide the highest image resolution.
The current industry trends are geared towards addressing quality challenges in advanced manufacturing technologies. As parts become more intricate, traditional quality control methods fall short, which is where industrial X-ray imaging truly shines. The ability to see inside parts makes industrial X-ray ideal for non-destructive defect detection, and it is also excellent for comprehensive inspection, from defect detection for quality control to precise measurements.
Like other industries, we see the advantages of using AI and machine learning in the entire process chain, from defect detection in both 2D and 3D X-ray images to innovative image acquisition for faster scans. There are also exciting advancements coming from the brighter, higher-resolution industrial X-ray sources and improvements in the sensitivity of detection technologies.
… since NSI's acquisition by Illinois Tool Works, how has this partnership influenced your approach to innovation and product development?
NSI was founded in 1986 to bring industrial X-ray testing to the manufacturing industries and has introduced market-leading solutions in both digital radiography (DR) and computed tomography (CT). In 2010, NSI was acquired by Illinois Tool Works (ITW) and became part of its Test and Measurement segment. ITW is a diversified manufacturing company that follows a set of strategic, operational, and cultural practices developed over more than 30 years. The ITW Business Model is built around three key elements: the 80/20 Front-to-Back Process, Customer-Back Innovation, and a Decentralized, Entrepreneurial Culture. Customer-Back Innovation is a critical component of our strategy, providing a framework for creating innovative solutions to address our customers’ critical pain points.
… what are some of the most challenging problems you’ve encountered in developing state-of-the-art industrial X-ray and CT systems, and how have you addressed them?
There is an array of challenges our customers are facing in industrial manufacturing such as needing to process assemblies vs. each part of the assembly, new materials being developed, requirements for accuracy increasing and the constant chase for speed. At NSI, we offer a range of systems to accommodate different part sizes and energy needs, from 160kV sub-micron resolution imaging to inspect small parts to our 6 & 9 MeV systems, which can scan large, dense objects. Recently, we integrated a 450kV meso-focus X-ray source, which combines the best of both worlds: high energy and high resolution. When combined with our subpiX™ solution, we offer unparalleled image quality and resolution.
When it comes to increased accuracy, we’ve heard from our industrial x-ray system operators that they assume their system has ideal conditions, such as a perfect circular focal spot. We know when that assumption is made, it can lead to inaccurate and blurry images. Therefore, earlier this year we launched our new focal spot capability which provides the ability for our users to quickly evaluate the current conditions more accurately, signalling adjustments that make their view as clear as possible, leading to the most accurate evaluation possible.
… with the broad range of industries using NSI technology, from aerospace to medical devices, how do you prioritize and adapt to the diverse needs and applications of your clients?
Customer back innovation is one of the key aspects of NSI strategy that guides us in this regard. We have created a diverse range of configurable solutions to cover various industries and applications both in terms of the hardware and software capabilities.
… what inspires you to push the boundaries of innovation in your field? Are there any particular people, experiences, or ideas that have significantly shaped your approach?
My first job after my undergraduate degree was with Unilever India, where I had the opportunity to work as a research associate in corporate research. Our aim was to push boundaries and create futuristic solutions for everyday needs of consumers. I enjoyed that experience immensely and have carried that same spirit of innovation into every job I've held since then.
… can you share a project or accomplishment at North Star Imaging that you’re particularly proud of? What made it stand out for you?
NSI has a few unique solutions to address the resolution limitation posed by large samples. One of the most popular ones is called subpiX, which can effectively double or triple the image resolution while still imaging the entire volume using the same equipment. We know subpiX extends the length of the scan which led to our next software upgrade coming later this year, advanced subpiX, effectively allowing for double or triple image resolution at typical scanning speeds instead of the current extended timeframe.
… if you could design a dream project with unlimited resources, what would it look like, and how would it push the envelope of current NDT technologies?
A dream project would be to develop a high-resolution, multi-modal holistic inspection system capable of creating a digital twin. With advancements in industrial X-ray CT and correlative analysis, achieving this is now possible. The key challenge is to be to make such a solution both seamless and cost-effective, so it can be applied beyond the research arena and into practical, everyday use.
… what’s a typical day like for you as the Director of Innovation? How do you balance between managing your team and staying hands-on with technology?
I am fortunate to lead a highly talented and motivated group of engineers. During the early stages of a project, I am deeply involved in the hands-on work. Once the project progresses, I shift my focus to research, staying updated with the latest studies, and attending conferences. This balance allows us to create best-in-class systems while ensuring that I stay engaged with both the technical and strategic aspects of our work.
Dr. Pradeep, what advice would you give to someone aspiring to enter the field of technological innovation in NDT or related industries?
NDT is an exciting field with a bright future and offers opportunities to work across diverse applications, from aerospace and medical to automotive, oil and gas, and industrial-academic research. My advice to anyone aspiring to innovate in this field is to maintain an open mindset, develop the ability to cut through the clutter and have a strong drive to simplify complex problems.
… outside of work, do you have any hobbies or interests that might seem surprising given your focus on high-tech innovation?
When I am not at work, I love to play badminton, dabble in cricket, going on roller coasters with my daughter, and, to my family’s horror, attempt to innovate in the kitchen!
… are there any books, movies, or shows that you enjoy that might offer an unexpected perspective on your work or innovation in general?
Recently, I re-read The Design of Everyday Things by Don Norman with our engineering team, and I highly recommend it to all engineers and innovators. It provides valuable insights into human-centred design and shows how thoughtful design can lead to better products and solutions. I also recommend the BBC podcast 13 Minutes to the Moon, which tells the story of the technology behind the Apollo 11 mission and highlights the problem-solving and ingenuity of the astronauts during the Apollo 13 mission.
… as someone deeply involved in advanced technology, do you have a favourite gadget or piece of tech that you use regularly?
I don’t have a favourite gadget as such, but I have recently been experimenting with AI assistants to help me search through a large number of research papers. These tools have been quite useful in extracting and summarizing key information, which significantly enhances my ability to stay current with the latest advancements in our field.
… if you could invite any historical or contemporary figure to join your team for a brainstorming session, who would it be and why?
For me it would be Jony Ive, the former Chief Design Officer at Apple. His innovative design philosophy and ability to blend aesthetics with functionality and user experience could inspire fresh, creative approaches to our work in X-ray and CT systems.
… what are some of your personal and professional goals for the next five years, and how do you envision your role evolving within the technology landscape?
I joined NSI as the Innovation Director a year ago. Over the next 5 to 10 years, my goal is to leverage our outstanding engineering and research teams to tackle the challenges faced by both our industrial and research customers.
Finally, what are your thoughts on OnestopNDT? Do you think our efforts to provide real, authentic and accurate content are helping the industry? Also, do you think our platform helps the community connect with like-minded people?
OnestopNDT is a valuable resource that I frequently use to stay updated on the latest developments in NDT technologies, including X-rays. It helps me keep track of upcoming conferences and learn about other companies with interests similar to those of NSI. This platform is excellent for connecting with like-minded people in our industry and for advertising and recruiting talented individuals from around the world. I look forward to collaborating closely with this platform, and I appreciate the opportunity to participate in this interview.
