Machine Vision for Fabrication, Machining, and Parts Manufacturing

Dynamic Design & Manufacturing, Inc. (Dyco) is a world leader in fabrication and machining. Their customers range from the US military to major contractors in defense, security, manufacturing, technology, and aerospace. The bar is set very high since it is normal for contractual obligations to demand tolerances down in the micron level. Dyco is ISO 9001-2008 certified, therefore, management and customers expect that 100% of manufactured parts to match specification.

Even with the most precise machining tools in the world, capable of cutting and moving thousands of pounds of materials around a table with accuracy and ease, there are still extensive issues of calibration and the requirement for measured verification. The cost of human inspection is measured in terms of both time and money. The focus was on delivering quality product, issues such as reporting, learning, adapting, and reliability are often put aside and can be slippery for management to obtain. The question Dyco’s management started asking was, “Is there a proven technology that can reliably improve quality throughout the precision parts manufacturing process?”. 

In exploring the market for a solution Dyco found various systems that are designed to ensure parts accuracy – mostly laser systems that have various problems including calibration, performance, inflexibility, maintenance, expandability at a reasonable cost, and others. However, a true breakthrough happened when the management team discovered a more effective path to success utilizing state of the art vision solutions. Dyco’s attention turned to Boulder Imaging who was able to act as a solutions partner capable of ultimately delivering even more then they had even dreamed was possible.

Precision Machine Vision System to the Rescue

Boulder Imaging’s Vision Inspector™ Benchmark system eliminates the constraints of fixed inspection that requires manual movement of individual parts for random spot inspection. Dyco can now examine their parts in-line during fabrication. There is absolutely no interruption to their production process. In addition, the production event can be recorded for real-time review. Now instead of only spot inspection, complete inspection is possible.

Additionally, Boulder Imaging introduced Dyco to their Benchmark system to address First Article Inspection requirements as well as CAD to Vision and Vision to CAD demands. “Boulder Imaging is able to provide Dyco with complete solutions not just a piecemeal approach. This is due to our extensive product offerings. We pride ourselves on solving entire production process and workflow issues. Using that methodology we can fully exploit our vision technologies to provide scaled efficiencies. When presented to customers such as Dyco the ROI becomes a total no brainer,” states Boulder Imaging’s CTO Carlos Jorquera.

Boulder Imaging also has the Vision Inspector™ Guardian that monitors machine behavior, providing high resolution video for forensic analysis when anomalies occur along with regulating capabilities for production machinery. A lot of systems monitor and alert but few are able to do so as comprehensively (with our multiple high resolution 24/7 multiple cameras solutions) intelligently, and flexibly as the Guardian. Carlos states, “We are really excited to be working with Dyco because they are committed to total quality and eliminating product waste and will do so through implementing our systems throughout their production process.”