RESONIKS has unveiled the QCFlex, a standalone automated inspection system designed to bring AI-powered acoustic defect testing directly to production lines. The solution enables manufacturers to perform fast and reliable 100% inspection of complex components, supporting the detection of structural defects across a wide range of materials and applications.
Developed for seamless in-line integration, the QCFlex combines advanced acoustic sensing, robotics, and artificial intelligence to automate quality control processes. The system is designed to inspect manufactured parts after production processes, providing rapid pass/fail decisions based on acoustic signatures generated during testing.
At the core of the system is RESONIKS’ second-generation sensor technology. The company’s in-house developed MP2 microphones feature a high signal-to-noise ratio and are fully calibrated to eliminate variation between sensors. Operating across a bandwidth range from 20 Hz to 80 kHz, the microphones capture acoustic responses generated by the SH2 precision hammer.
Mounted on a high-accuracy SCARA robot, the SH2 delivers controlled impacts with adjustable force to ensure fully reproducible testing conditions. Sensor arrays then record the resulting acoustic fingerprints of each component, generating data for AI-driven analysis.
The collected acoustic signals are processed by machine learning models trained specifically for defect detection applications. According to RESONIKS, the system can convert inspection results into pass/fail decisions within seconds.
“Our machine learning team applies full audit trail by design, making no decision ever a black box,” highlighted Fabian Oberndorfer, RESONIKS’ CTO.
The QCFlex has been engineered for industrial environments and incorporates a closed-loop design with an automated opening and closing mechanism to maintain performance under challenging conditions, including vibration, temperature fluctuations, humidity, and dust exposure.
The inspection platform also features a robotized and interchangeable fixture system, allowing users to test multiple part types within the same machine. The system supports components up to 800 mm in size and weighing up to 200 kg. A newly developed touchscreen interface further enhances usability and operational flexibility.
The technology is capable of detecting both surface and internal structural defects in metal, composite, ceramic, and other rigid materials, expanding inspection possibilities for manufacturers seeking automated non-destructive testing solutions.
In addition to the hardware platform, RESONIKS provides in-house product support services covering system setup, technical assistance, and maintenance. The company positions QCFlex as a scalable solution that can support quality assurance initiatives while improving manufacturing efficiency.
“By integrating the QCFlex early in the production line, manufacturers can reduce their production costs and make their production process significantly more sustainable. This directly increases the OEE (Overall Equipment Effectiveness),” said Felix Wassmann, CEO of RESONIKS.
The launch marks a significant milestone for RESONIKS as it transitions from pilot projects to full industrial deployment of its acoustic inspection technology. The company noted that the achievement follows the successful completion of its seed investment round and builds on the momentum gained after receiving the 2025 VDMA Startup Award.
Reference: https://metrology.news/qcflex-offers-fully-automated-ai-powered-acoustic-testing/
