𝐼yenX

Lessons in X-ray inspection

Made for complete beginners. Pick a lesson, then swipe or tap the arrows.

New lessons are added regularly.

1X-rays 101Start here. The absolute basics.2What X-rays seeExamples from real industries.3Scans that save moneyWhy it pays off.
42D or 3D?Which one do you need?5Inside the scannerKnow the parts.6Golden rules of scanningFrom door to data.
7CT in the labPrototypes, failures, materials.8CT on the lineTowards 100% inspection.9CT for everyday goodsFrom scan data to profit.
10AI and roboticsScanning at high volumes.
Lesson 1

X-rays 101

Start here. Zero physics needed.

WHY IT PAYS Lesson 1 · X-rays 101 See inside. Sell it anyway. An X-ray scan looks without breaking anything. Every part you don’t cut open is a part you can still ship. 𝐼yenX
Fact 1 Light you can’t see. X-rays are light, with far more energy. radiomicroIRlightUVX-rayslong wavelengthshort wavelengthless energymore energyyou see thisX-ray view 𝐼yenX
Fact 2 Made in a tube. Fast electrons hit metal. Out come X-rays. cathode (−)tungsten filament electrons, sped up by the voltage anode (+) window X-rays 𝐼yenX
Fact 3 They pass through things. Thin and light lets more through. Thin plasticmost get through Thick steelfew get through 𝐼yenX
Fact 4 Shadows make the picture. A detector records what gets through. source object detector The shadow is the X-ray image. 𝐼yenX
Fact 5 Rotate for 3D. Rotate the object and X-rays see it from every side. rotate the object 0°45°90° flat images from every angle 3D model of the gear A computer combines them into 3D. 𝐼yenX
Fact 6 Denser materials, deeper shadows. Every material casts its own shade. foamwoodplasticaluminiumsteelleadon the X-ray image:denser → stops more X-raysComputers often flip the colours:denser materials show up brighter. 𝐼yenX
Fact 7 Safe when shielded. Industrial cabinets keep the X-rays inside. lead lining side doorinterlock: lockedwhile scanning X-rays stay inside. You stay safe outside. 𝐼yenX
X-RAYS VS. CHOCOLATE X-RAYS VS. LEAD Straight through.Not today. DENSITY DECIDES. Light materials let X-rays through. Dense ones stop them. 𝐼yenX
JARGON CARD Attenuation Say it: a-TEN-you-AY-shun IN PLAIN WORDS How much an object weakens X-rays as they pass through it. Thicker parts, denser materials and heavy metals weaken them more. WHY IT MATTERS It is what makes the image: the shades you see are differences in attenuation. 𝐼yenX
Summary In a nutshell. The main points of this lesson. X-rays are light you can’t see, with much moreenergy than visible light.They are made in an X-ray tube, when fast electronshit a metal target.Dense materials let fewer X-rays through.The detector records what gets through: that shadowis the X-ray image.Rotate the part and you get a 3D scan.A lead-lined cabinet keeps the X-rays inside, sopeople outside are safe. 𝐼yenX
Next lesson: What X-rays see
Lesson 2

What X-rays see

Real industries. Zero hospitals.

It’s more than a picture: X-ray scanning measures parts, compares them with CAD, checks alignment, and counts and sizes what it finds.

WHY IT PAYS Lesson 2 · What X-rays see What you can’t see, you’re already paying for. Hidden voids, cracks and misfits come back later as returns, recalls and warranty claims. 𝐼yenX
Example 1 Packaging Seal, fill, pores and contaminants. Unopened. outside X-ray view HONEY sealed · 450 g seal gap target fillfill too low glass splinter(contaminant) air pocket(pore) Sealed jar Four faults, found 𝐼yenX
Example 2 Home electronics Solder joints inside your gadgets, voids measured. outside X-ray view CHIP void 18 % · bridge Circuit board Voids, measured 𝐼yenX
Example 3 Batteries Folds and stray particles inside a sealed cell. outside X-ray view top-down slice · fold and particle Battery cell Fold and particle found 𝐼yenX
Example 4 Medical devices Every part in place, without opening it. outside X-ray view Auto-injector pen Spring seated wrong 𝐼yenX
Example 5 Wellness Supplements checked for coating and cracks. outside X-ray view thin coat · crack Vitamin tablet Thin coating, crack 𝐼yenX
Example 6 Fine food Metal and bone, caught before you swallow. outside X-ray view on the line, at full speed Fine chocolate Metal fragment, caught 𝐼yenX
Someone: “Isn’t X-ray just for broken bones?” NOPE. IT ALSO CHECKS CHOCOLATE, BATTERIES, CHIPS AND WATCHES. 𝐼yenX
Example 7 3D printing Lattices no caliper can reach. outside X-ray view Printed metal part Broken strut, stuck powder 𝐼yenX
Example 8 Heritage Look inside without a chisel. outside X-ray view Lump of rock Fossil, untouched 𝐼yenX
Example 9 Artisanal cheese Counting the holes without cutting the wheel. outside X-ray view AGED 12 MONTHS size, count, spacing Cheese wheel The holes, checked 𝐼yenX
Example 10 Giant parts Whole pallets, in one scan. outside X-ray view ~1.2 m every item where it belongs? A full pallet Contents, checked 𝐼yenX
Example 11 Small part, fine detail. The smaller the part, the finer the detail. Small parts Big parts chipsbattery cells castingswhole pallets microns down to nanometres hundreds of microns to millimetres finest detail big parts, coarser detail 𝐼yenX
Someone: “I need nanometre resolution.” Also someone: BIG PART = LESS FINE DETAIL. Nanometre detail is for tiny samples, not whole fridges. 𝐼yenX
JARGON CARD Grey value The number behind every shade IN PLAIN WORDS The brightness of one pixel in an X-ray, or one voxel in CT. It is a number, not just a shade of grey. WHY IT MATTERS Different grey values usually mean different materials or densities, so you can tell air, plastic and metal apart. 𝐼yenX
Summary In a nutshell. The main points of this lesson. X-rays show the inside of products without cuttingthem open.Packaging and food: seal gaps, fill levels, airpockets, glass or metal.Electronics, batteries, medical devices, 3D-printedparts, even fossils.Giant parts, like pallets and large castings:detail from hundreds of microns to millimetres.Small parts, like chips and battery cells: detaildown to microns, even nanometres.The smaller the part, the finer the detail you cansee. 𝐼yenX
Next lesson: Scans that save money
Lesson 3

Scans that save money

Why it pays off.

WHY IT PAYS Lesson 3 · Scans that save money A scan costs minutes. A recall costs years. Finding a defect at the line is cheap. Finding it in the news is not. 𝐼yenX
Saving 1 Stop cutting parts open. Look inside and keep the part. Cut open: part lost Scanned: part kept 𝐼yenX
Saving 2 Catch it early. Found in the factory, it’s cheap. Later, it isn’t. factoryassemblyin usethe later it is found, the more it costs€€€€€€ 𝐼yenX
Saving 3 Fewer recalls. Find it before anyone else does. RECALL Found after delivery Found by you, first 𝐼yenX
Saving 4 Faster development. See inside prototypes. Fix them sooner. Without X-raysbuild · test · cut · guess · repeat With X-raysbuild · scan · fix weeks saved time 𝐼yenX
Saving 5 Less scrap. Find the root cause. Fix the process. root cause found with X-raysscrap per month 𝐼yenX
Saving 6 Compare suppliers. See inside every supplier’s part. Supplier ASupplier B outside: looks fineoutside: looks fine X-ray: solid insideX-ray: hidden pores No more black-box anxiety. Choose suppliers on evidence, not promises. 𝐼yenX
Saving 7 Automate inspection. Hundreds of parts an hour, around the clock. By handAutomated a few partsper hour OK ✓ hundreds per hour The scanner checks. People review flagged images. 𝐼yenX
Saving 8 Data that improves the process. Every scan feeds the statistics. limit: scrap drift spottedearly pore size, every part, over the day Fix the drift before it becomes scrap. 𝐼yenX
Saving 9 No QC pile-ups. Fast inspection keeps gigafactories safe and moving. Slow QCFast, automated X-rayQC!unchecked cells pile upa safety and fire riskevery cell checked in secondsthe line keeps movingAutomated, fast X-ray stops dangerousQC pile-ups in gigafactories. 𝐼yenX
Saving 10 Savings add up over time. The investment pays back, then keeps paying. break-even investment net savingsgrow monthly 0 startyear 1year 2year 3 Pay once. Save every month after. Illustration: the real numbers depend on your parts and volumes. 𝐼yenX
Saving 11 Start small. Try before you invest. 1Test scansat a lab or supplier2Decidewith real images3Investonly if it paysSmall first steps, low risk. 𝐼yenX
WHEN YOU FIND THE DEFECT… in the factoryat assemblyafter delivery FIND IT EARLY. FIND IT INSIDE. 𝐼yenX
JARGON CARD NDT Non-destructive testing IN PLAIN WORDS Checking a part without cutting, breaking or damaging it. X-ray and CT are both NDT methods. WHY IT MATTERS You keep the part. The same part can be tested, shipped and sold, and that saves money. 𝐼yenX
Summary In a nutshell. The main points of this lesson. Scanning checks the inside without cutting partsopen and destroying them.A defect caught in the factory costs far less thanone found after delivery.Fewer recalls, less scrap and shorter developmentloops.Compare suppliers on evidence: hidden pores show upin the scan.Automated scanning checks hundreds of parts an hourand feeds process data.Start with test scans at a lab; invest once thesavings are clear. 𝐼yenX
Next lesson: 2D or 3D?
Lesson 4

2D or 3D?

Flat image or full 3D? Here’s how to choose.

Most X-ray scanning in production is now highly automated and computerised: the scanner and its software do the work, and people mostly look at the images.

WHY IT PAYS Lesson 4 · 2D or 3D? Buy the answer, not the machine. 2D gives a yes or no in seconds. CT tells you how much and where. Pay for what your question needs. 𝐼yenX
Fact 1 2D: one shadow. One X-ray image. Quick and simple. 1 image: nuts overlap One flat picture, straight through. Everything along the beam overlaps. 𝐼yenX
Fact 2 3D CT: many shadows. The part turns. A computer builds it in 3D. part turns hundreds of images 3D volume on screen A computer turns them into 3D. Then slice it any way: top, front or side. 𝐼yenX
Fact 3 3D shows depth. Defects can hide behind each other in 2D. 2D image3D slices Looks like one Actually two 𝐼yenX
Fact 4 3D measures inside. Walls, cavities and dimensions you can’t reach. a slice through a shampoo bottle hidden inside,measured without cutting wall 2.1 mm outer width 60 mm Thin walls, measured to a fraction of a millimetre. 𝐼yenX
Fact 5 How long does a scan take? From seconds to hours, depending on the detail. 2D X-rayProduction CT(3D scan)Research CT secondsseconds tominutes to minuteshours every part,on the line every part orselected parts the finestdetail More scan time buys finer detail. 𝐼yenX
Fact 6 2D is fast. 3D is thorough. In production, both can be combined. 2D X-ray3D CT sourcesource detector under the beltdetector under the belt one image, quick yes/nospins in a circle every drone, in secondsfull 3D detail Combine both: 2D screens, CT looks closer. 𝐼yenX
Fact 7 3D is everyday. CT is used daily in production and in R&D. Castings Batteries Electronics 3D printing 𝐼yenX
Fact 8 Software finds defects. Modern scanners are highly automated. AI check 3 defects sized and located Part: reject Scanning is automated. Software searches. People look at the images and make the call. 𝐼yenX
Fact 9 Which one do I need? Side by side. 2D X-ray3D CTYou getone flat imagea full 3D volumeSpeedsecondsseconds to hoursFindsforeign bodies, missingor misplaced partshidden defects, whereand how bigMeasuresoutlines, fill levelswalls, cavities, CADdeviationsUsed inproductionproduction and R&DCostlowerhigher 𝐼yenX
JARGON CARD Voxel A 3D pixel IN PLAIN WORDS The tiny cube a CT volume is built from. Like a pixel in a photo, but with depth. WHY IT MATTERS Voxel size limits the smallest detail you can see. Smaller voxels: finer detail, but less of the part fits in one scan. 𝐼yenX
Summary In a nutshell. The main points of this lesson. 2D X-ray: one flat image in seconds, whereeverything along the beam overlaps.3D CT: hundreds of images from every angle, rebuiltinto a 3D volume you can slice.CT shows depth and measures walls and cavities youcan’t reach.2D takes seconds; production CT seconds to minutes;research CT minutes to hours.In production, combine them: 2D screens every part,CT looks closer. 𝐼yenX
Next lesson: Inside the scanner
Lesson 5

Inside the scanner

All the parts explained simply.

Modern scanners are highly automated and computer-controlled. Knowing the parts helps you read the images, which is what people mostly do.

WHY IT PAYS Lesson 5 · Inside the scanner Same few parts, endless setups. Every CT system reuses the same core parts, arranged differently for each job. Learn them once and you can read any scanner. 𝐼yenX
Part 1 The X-ray source. The engine of every scanner. X-ray source (tube)X-rays out ⚡ high voltage in Voltage sets how hard X-rays punch. Current sets how many. 𝐼yenX
Part 2 The detector. Catches what gets through. detector Millions of pixels record every shadow. Types include flat-panel, CMOS and photon-counting detectors. 𝐼yenX
Part 3 The turntable. Where the part sits and rotates. rotates The part sits here and turns for 3D. 𝐼yenX
Part 4 2D stays still. 3D rotates. Same scanner parts, different motion. 2D X-ray3D CT stays still: one imagerotates: hundreds of images 𝐼yenX
Part 5 The manipulator. Moves the part, source and detector. three parts, imaged one at a time part moves towards source or detector up / down up / down Motors and rails set zoom and field of view. 𝐼yenX
Someone: “How many kV? How many pixels?” Also someone: forgets the turntable’s max load. GIANT CHEESE WHEEL CHECK THE MAX LOAD. Heavy parts need a manipulator rated for them. 𝐼yenX
Part 6 The shielded cabinet. Keeps the X-rays inside. warning light inside: lead lininginterlockdoor lockeddoor, closed X-rays stay in. People stay safe outside. 𝐼yenX
Opening the door mid-scan: X-RAYS OFF source detector parts manipulator open doorway door, open interlock INTERLOCK SAYS NO. Open the door and the X-rays switch off. By design. 𝐼yenX
Part 7 The computer. Controls the scan, builds the 3D. scan settingsreconstructionanalysis Runs the scan, then builds and measures the 3D. 𝐼yenX
DetectorSoftware 0°45°90°135° “I only see shadows.” “Hold my 3D.” SHADOWS IN. 3D OUT. 𝐼yenX
Part 8 Source, part, detector. Always in one line. sourceparts, stacked:one in the beamdetector Every scanner, from airport to lab, has these three. 𝐼yenX
Part 9 2D in production. Source above, detector below. source, overheaddetector, under the beltcookies lie flatX-ray-transparent conveyor belt Every cookie checked in seconds. 𝐼yenX
Part 10 3D in production. The belt runs through a spinning gantry. gantry spins fastsourcedetectorbelt runs throughthe gantry 𝐼yenX
Part 11 Closer to the source = bigger. Move the part to zoom in. near the source: big image, fine detail near the detector: small image, whole part 𝐼yenX
Part 12 All together. The basic parts of every scanner. 1. source2. detector3. turntable4. manipulator 6. computer5. shielded cabinet (outside)warning lightdoor interlock Source, detector, turntable, manipulator, cabinet, computer. 𝐼yenX
JARGON CARD Focal spot Where X-rays are born IN PLAIN WORDS The tiny spot on the tube’s target where the X-rays are made. WHY IT MATTERS Smaller spot, sharper image. A big spot blurs edges, like the soft shadow from a wide lamp. 𝐼yenX
Summary In a nutshell. The main points of this lesson. The source makes X-rays, the detector records theshadow, and the turntable rotates the part for 3D.The manipulator moves the part: closer to thesource means a bigger image and finer detail.The lead-lined cabinet and door interlock keep theX-rays inside.The computer rebuilds the shadows into a 3D volume.All scanners share these same parts, just inslightly different orientations. 𝐼yenX
Next lesson: Golden rules of scanning
Lesson 6

Golden rules of scanning

Twelve rules. No excuses.

Most scanners today are highly automated and computerised. These rules are for the moments people set up a scan, so the images they look at are sharp and everyone stays safe.

WHY IT PAYS Lesson 6 · Golden rules of scanning A bad scan lies with confidence. Good habits turn every scan into a result you can put your name to. 𝐼yenX
Rule 1 Door shut. Always. Never bypass the interlock. Jammed interlock interlock: door locked Door shut, lamp on 𝐼yenX
Rule 2 Warm up the X-ray tube. Cold tube, drifting X-ray spot. Cold start X-ray spot position X-ray spot position Warmed up 𝐼yenX
SKIPPING THE TUBE WARM-UP Expectation Reality 20 minutes saved! Unstable X-rays. Scan ruined. SAVED 20 MINUTES. LOST THE AFTERNOON. 𝐼yenX
Rule 3 Set the tube's voltage and current. Voltage pushes through. Current brightens. Step 1: voltage up until the thickest part shows through Darkest spot: not black Step 2: current up until the brightest spot is just below full full Brightest spot: not white 𝐼yenX
Rule 4 Filter the beam. Dense metal? Copper or tin in front of the tube. Cu / Sn hard X-rays only steel gear dark centrebrightedge No filter: cupped Filtered: even 𝐼yenX
Rule 5 Set the detector. Frame rate and integration time. Then calibrate. detector Frame rate 5 fps Integration 200 ms Longer integration = fewer frames per second. Too short: noisy Long enough: smooth 𝐼yenX
Rule 6 Calibrate the detector. Easy: one button press. Before every session. GO + = Beam off Beam on, empty Even images Skipped: faint stripes Calibrated: clean 𝐼yenX
Rule 7 3D spins. 2D stays still. Pick the mode, then set the stage. 3D CT voxels Rotates: many angles 2D X-ray pixels Fixed: one angle 𝐼yenX
Rule 8 Spin before you scan. One slow turn. No bumps. top view top view BONK Hits the tube gap Clear all round 𝐼yenX
Rule 9 Nothing may wobble. Fix it firmly: foam, tape or clamps. Just balanced Foam and tape 𝐼yenX
Me: “It'll stay put.” The scan: IT MOVED. IT BLURRED. 𝐼yenX
Rule 10 Tilt the part just a little. Any part, not just flat ones: 10–20° off upright. Flat: streaks 15° Near upright, 10–20° off 𝐼yenX
Rule 11 Stay in the picture. The whole part, at every angle. Or extend the scan upwards or sideways. top view top view Red bits: incomplete image All inside the beam 𝐼yenX
Rule 12 3 voxels or it didn't happen. Set up the scan and resolution so the feature or defect you care about is at least 3 voxels wide. real pore in red Tiny pore: invisible 3 voxels 3 voxels wide: found 𝐼yenX
Enjoy your nice X-ray data. 3D model Every rule followed. Every detail sharp. 𝐼yenX
JARGON CARD Beam hardening Why dense parts show streaks IN PLAIN WORDS As X-rays pass through dense material, the low-energy ones are absorbed first, so the beam that is left is “harder”. WHY IT MATTERS In CT it causes streaks and falsely dark centres (“cupping”). A thin metal filter at the tube helps reduce it. 𝐼yenX
Summary In a nutshell. The main points of this lesson. Door shut, interlock never bypassed; warm up thetube before scanning.Set voltage first, then current; filter dense metalwith a copper or tin plate.Set frame rate and integration time, then calibratethe detector.Rotate the part once before scanning to check itclears the tube.Fix the part so nothing wobbles, tilt it 10 to 20degrees, and keep it in view at every angle.Make the smallest detail you need at least 3 voxelsacross. 𝐼yenX
Next lesson: CT in the lab
Lesson 7

CT in the lab

From R&D labs. All consumer products.

Research scans take longer for finer detail, but the scanning and analysis are just as computerised: researchers mostly look at the images.

WHY IT PAYS Lesson 7 · CT in the lab You paid for the failure. Now read it. CT shows why a prototype broke, so the next one doesn’t. 𝐼yenX
Research 1 See inside prototypes. Look inside a new product. No screwdriver. outsideX-ray viewspeaker · battery · antennaPrototype earbudSpeaker off-centre 𝐼yenX
Research 2 Find out why it failed. Failure analysis, without destroying the evidence. outsideX-ray viewone wire snapped insideReturned charger cableBroken wire, foundFind the cause. Fix the design. 𝐼yenX
Research 3 Measure the structure. Bubbles, pores and crumb, counted in 3D. outsideCT slicesmallmidlargeSourdough loafEvery pore, sized 𝐼yenX
Research 4 Compare with the design. Does the 3D-printed frame match its CAD? bridge 0.3 mm off on CADoff CAD Dashed: the design. Colour: the real part. 𝐼yenX
Research 5 Watch it change. Scan the same product before and after testing. newafter 1,000 km round foam cellsheel cells crushed Running shoeFoam worn at the heel 𝐼yenX
Research 6 The finest detail takes time. Research scans run for minutes to hours. minutes to hours hair dryermotor windings, wire by wirea 1 mm crack in a winding More scan time buys finer detail. Production scans take seconds; research scans can take hours. 𝐼yenX
Research 7 Computers do the heavy lifting. Scanning and analysis are automated. ✓ builds the 3D✓ counts pores✓ measures walls✓ writes the report Software runs the scan and the maths. Researchers look at the images and decide. 𝐼yenX
JARGON CARD Segmentation Sorting the scan into parts IN PLAIN WORDS Splitting a CT volume into what it is made of (air, plastic, metal, pores), mostly by grey value. WHY IT MATTERS It comes before almost every measurement: wall thickness, pore size, fit and assembly. 𝐼yenX
Summary In a nutshell. The main points of this lesson. See inside prototypes and find out why returnedparts failed.Measure internal structure, like every pore, innumbers.Compare the scanned part with its CAD design to seewhere it is off.Scan before and after testing to see how thematerial changes.The finest detail takes longer: research scans runminutes to hours.Software builds the 3D volume, measures andreports; researchers interpret. 𝐼yenX
Next lesson: CT on the line
Lesson 8

CT on the line

From the factory floor. All consumer products.

We are moving towards 100% inspection: CT now takes seconds and modern computers are fast. Production X-ray is highly automated, and people mostly look at the flagged images.

WHY IT PAYS Lesson 8 · CT on the line Sampling is hoping. Scanning is knowing. Checking every part turns “probably fine” into proof, part by part. 𝐼yenX
Production 1 Inline inspection. Products are checked on the moving line. warning lightlead curtains detectorshielded tunnel over moving line Every ready meal, scanned as it passes. Checked for bone, glass, metal and stone. 𝐼yenX
Production 2 Towards 100% inspection. From checking a few to checking every one. Sampling100% inspection 1 in 100 checkedevery part checked CT now takes seconds, and computers are fast. 𝐼yenX
Production 3 CT in seconds. What once took hours now takes seconds. Thenhours per part Nowseconds per part ✓ faster detectors✓ stronger X-ray sources✓ fast computers rebuild the 3D in real time Fast enough to keep up with the line. 𝐼yenX
Production 4 Automatic accept or reject. Bad products are pushed off the line. source detector under the belt spins for 3D reject bin good bottles carry on Software decides in real time. The line never stops. 𝐼yenX
Production 5 Where it’s used. Consumer products, checked on the line. Consumer electronicssmartphones, laptops,tablets, earphonesLuxury goodswatches, jewellery, handbagsFine foodchocolate, cheese, bottled goods 𝐼yenX
Production 6 Data that improves the process. Every scan feeds the statistics. limit: scrap drift spottedearly pore size, every part, over the day Fix the drift before it becomes scrap. 𝐼yenX
Production 7 People look at images. Modern lines are highly automated. 1 flagged The scanner runs itself. People review only the flagged images. 𝐼yenX
THENNOW “We check 1 in 100.”“We check all 100.” EVERY. SINGLE. ONE. 100% inspection is now normal, achievable and affordable. 𝐼yenX
JARGON CARD Cycle time Seconds per part IN PLAIN WORDS The time it takes to handle one part: load, scan, check and unload, before the next one comes in. WHY IT MATTERS On a production line, CT must keep pace. Short cycle times make 100% inspection possible. 𝐼yenX
Summary In a nutshell. The main points of this lesson. Products are X-rayed on the moving line, inside ashielded tunnel.CT now takes seconds, so checking every part (100%)is possible.Software accepts or rejects each part in real time,without stopping the line.Every scan feeds process statistics, so drift iscaught before it becomes scrap.The scanner and software run the checks; peoplereview the flagged images. 𝐼yenX
Next lesson: CT for everyday goods
Lesson 9

CT for everyday goods

Food, drinks, packaging, safety gear, e-scooters, projectors and everyday products.

A CT scan isn’t a picture. It’s numbers: every pore, wall and seal, measured in 3D. That’s the value.

WHY IT PAYS Lesson 9 · CT for everyday goods At a billion units, one gram is a business plan. CT measures every wall, pore and seal, so tiny savings repeat on every unit you make. 𝐼yenX
FMCG 1 Read by software. Analysis modules pull out the main points. Porosity every pore, sized Wall thickness thin spots, mapped CAD compare off-design areas 12.40 Dimensions sizes, flatness, fit Assembly gaps and contact Foam cell size, density Fibres fibre direction Numbers out a short report Gigabytes in, a short list of numbers out. Numbers you can act on: faster decisions, less rework. 𝐼yenX
FMCG 2 3D data. Features of 10–100 µm, seen in 3D. cork + cage CT champagne DETECTOR · CORK IN THE BOTTLE MOUTH bottle mouth pores 10–100 µm linked pores let oxygen in air glass grey scale: darker = less dense Cork pores let oxygen in and steer how wine ages. Grade corks by scan: fewer spoiled bottles. 𝐼yenX
FMCG 3 Cracks, thin walls, wear. What matters most in a plastic buckle. plastic buckle, CT slice of the latch EXAMPLE DATA cracks found1 crack length0.4 mm thinnest wall (min 1.0)0.9 mm latch face worn0.15 mm Pores: only 0.3 %. Not the risk in this part. Cracks and thin walls fail first. Find them, avoid recalls. 𝐼yenX
FMCG 4 Round or ragged? Pore shape points to the cause. EXAMPLE: DIE-CAST E-SCOOTER STEM metal in gate thick hinge blockpore reaches surface Round = gas bubble air trapped while filling Ragged = shrinkage metal shrank as it cooled Round: check filling. Ragged: check cooling. A scooter frame can be quite porous. The question: do pores reach the surface? Then rain gets in and it corrodes. 𝐼yenX
FMCG 5 Location matters. Spirits caps: measure where each pore sits. pore in the top pore in the seal ring 0.3 mm · OK 0.3 mm · leak risk dashed ring = the seal, seen through the cap Same size, different risk. Strict only where it seals: less scrap, no leaks. 𝐼yenX
FMCG 6 Thickness everywhere. The whole wall, mapped in colour. thinnest: 0.18 mm target: at least 0.25 mm thinon target Lightweighting: 1 g less plastic per bottle × 100 million bottles = 100 tonnes EXAMPLE DATA Thin enough to save, thick enough to hold. 𝐼yenX
FMCG 7 Grams become money. Lightweighting pays back every single year. EXAMPLE DATA 1 g less PET per bottle × 100 million bottles a year 100 t less plastic a year resin saved (at ~€1.2 per kg)≈ €120,000 / yr CO₂ avoided (~2–3 kg per kg PET)≈ 200–300 t / yr plastic-packaging taxeslower, where they apply pallets and truckslighter loads One scan-guided change, paid back every year. CT shows how thin you can go, safely. 𝐼yenX
FMCG 8 Compare with CAD. See exactly where the part is off. menstrual cup, digitally sliced dashed line = CAD design +0.12 mmrim too thick: seal can leak ±0.02 mmfunnel curve on target:flow drops in, not around −0.08 mmstem tip not filled too smalltoo big EXAMPLE DATA CAD sets the curves that guide flow into the cup. CT checks them. Fix the mould before launch: fewer leaks, more comfort. 𝐼yenX
FMCG 9 Inside the shoe. Safety footwear, checked without cutting. safety shoe, seen through by CT EXAMPLE DATA Toe capseated, 0.6 mm off-centre Anti-penetration insertfull sole coverage, no gaps Midsole foamdensity varies 6 % heel to toe Sole bond0.5 mm glue gap at the heel Safety toe caps must survive a 200 J impact (EN ISO 20345). Pass the impact test first time: fewer costly re-tests. 𝐼yenX
FMCG 10 Safety gear, proven. Helmets and protective gear, seen inside. bike helmet, seen through by CT EXAMPLE DATA Shell wall2.1–3.4 mm, thinnest at a vent Foam liner60–68 g/L, one low spot After drop testhidden crack inside the liner Retention clipfully engaged Protective foam only works if it is all there. Test every design change without cutting costly samples. 𝐼yenX
FMCG 11 Measure it assembled. Side-release buckles, checked while closed. EXAMPLE DATA top latch: 1.5 mmengaged, OK bottom: 1.1 mmminimum is 1.2 mm side-release buckle (backpack, harness) · dashed = housing, seen through Also: springs seated, snap-fits, hinge pins, magnets. Only CT sees the latch while it is closed. Catch it before the strap lets go, and before a recall. 𝐼yenX
FMCG 12 Check seals unopened. Capsules, pouches and cans, seen through. coffee capsule ration pouch lubricant spray foil lid lifted: 0.2 mm at the rim coffee goes stale RATION channel in the seal: 0.3 mm must keep ~3 years LUBE spray valve crimp tight dip tube attached can still sellable EXAMPLE DATA The pack you check can still be sold. Spray cans: a loose valve crimp slowly leaks gas. 𝐼yenX
FMCG 13 Look inside the device. Smoke alarms, scanned fully built. smoke alarm, cut in half virtually EXAMPLE DATA Solder jointsvoids 14 % (limit 25 %) Battery contactspring presses the cell Smoke chamberlabyrinth warped 0.3 mm Buzzerpresent and fixed In Europe, smoke alarms are tested to EN 14604. It must work first time. A recall costs far more. 𝐼yenX
FMCG 14 E-scooters, inside. Every part can be scanned. 123 e-scooter: every part scannable EXAMPLE DATA 1 Battery pack1 cell swollen 0.5 mm 2 Folding hinge2 mm crack after 5,000 folds 2 Stem castingno voids near the bolt holes 3 Hub motormagnets bonded, gap even Folding joints and lithium cells are where e-scooters fail. Catch failures in the lab, not in warranty claims. 𝐼yenX
FMCG 15 Projectors, aligned. Lenses, chip and cooling, measured in place. projector, seen through by CT EXAMPLE DATA Lens stackelement 2 tilted 0.2° Imaging chipseated flat, centred Heat pipe0.3 mm gap at the LED Cooling fanblades clear the housing A tilted lens blurs one corner of the picture. Find it without teardown: less rework, fewer returns. 𝐼yenX
JARGON CARD Porosity Holes you can’t see IN PLAIN WORDS Tiny holes, gas bubbles or empty spaces inside a material. WHY IT MATTERS Pores can weaken a part or cause leaks. CT finds, counts and measures them in 3D without cutting. 𝐼yenX
Summary In a nutshell. How CT data saves money. CT DATA SAVES MONEY BY Wall thickness map→less plastic in every part Pore size and location→scrap only what is at risk Pore shape→fix the right process step Deviation from CAD→mould fixed in fewer loops Seal and latch checks→fewer leaks and recalls Scanned, not cut open→samples stay sellable Specific data, specific savings. Every number is a decision that pays. 𝐼yenX
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About IyenX

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IyenX was founded by Aishwarya Iyengar, PhD, with a simple objective: to share knowledge of advanced inspection technologies and make their potential more accessible across applications closest to the consumer.

Aishwarya Iyengar, PhD, founder of IyenX

With a background in materials chemistry and industrial X-ray inspection, Aishwarya is particularly interested in emerging applications where X-ray technology is still relatively unexplored, and in making the technology easier to understand, evaluate and apply.

Aishwarya holds a PhD in Materials Chemistry from Uppsala University.

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