Fraunhofer Institute for Production Technology IPT
Fraunhofer Institute for Production Technology IPT
© Fraunhofer IPT

OCT for production

The enormous advantages of optical coherence tomography can also be used for a wide range of applications in industrial production. In numerous research and industrial projects, the Fraunhofer IPT has also explored and further developed the potential of OCT outside the field of biomedical diagnostics.

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biological cell isolated on whithe background microscope 3D Illustration
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Whitepaper for download: OCT for 3D cell culture visualization

Learn more about how to visualize 3D cell cultures by using optical coherence tomogra-phy in our white paper.

more info

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© Fraunhofer IPT, Handheld provided by Thorlabs

Optical coherence tomography for biomedical diagnostics

With a penetration depth of several millimeters and a resolving power in the single-digit micrometer range, OCT allows high-resolution tissue analyses. For example, tumor tissue can be distinguished from healthy tissue at an early stage of disease.

© Fraunhofer IPT, Handheld provided by Thorlabs

Optical coherence tomography: non-destructive optical testing

Non-destructive quality control directly within the production process

When every micrometer counts: Optical coherence tomography (OCT) provides high-resolution 3D insights into transparent and semitransparent materials—noninvasively, quickly, and inline, directly within the production process.

OCT detects defects early on, directly during manufacturing, and delivers precise results for layer thickness measurement and structural analysis. It continuously monitors component quality and enhances the stability of production processes: even with complex geometries, a high level of quality assurance is guaranteed.

Custom OCT systems

At Fraunhofer IPT, we develop customized OCT solutions for manufacturing: from the selection of suitable components to intelligent analysis software and complete system integration.

Our technologies have already proven themselves in film processing, laser material processing, battery and semiconductor manufacturing, electronics production, and medical technology – anywhere where the highest quality standards, precise measurements, and reliable process control are critical.

Rely on our experience in research and industry, and let’s work together to measurably improve your production.

How OCT works

Optical coherence tomography (OCT) is a noninvasive imaging technique that allows for the tomographic examination of transparent and semitransparent materials. The operating principle of OCT is similar to that of ultrasound imaging. Unlike ultrasound, however, OCT uses light rather than sound waves. Depth-resolved cross-sectional images and volumetric 3D data provide detailed information about the internal structures of transparent and semitransparent materials. Tomographic measurements of the surfaces of nearly all materials are highly precise. With a penetration depth of several millimeters and a resolution in the single-digit micrometer range, OCT is about ten times better than ultrasound.

Our Services at a glance

  • Measurements of prototypes and small production runs
  • Feasibility studies for the use of OCT
  • Development of custom OCT systems for specific measurement tasks
  • Automation of measurement systems and synchronization with machines
  • Implementation of custom signal and image processing algorithms
  • In-house software for controlling OCT systems and integrating them with image processing systems

An overview of our OCT solutions

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Polarization-sensitive OCT

PS-OCT supplements traditional OCT measurement results with functional information – such as internal stresses in injection-molded parts, which can be determined based on their individual polarization properties.

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Full-Field OCT

Full-field OCT (FF-OCT) is a variation of conventional OCT. In this technique, the sample is illuminated across its entire surface by a microscope objective, and the reflected light is captured and analyzed by a flat-field camera.

High-resolution OCT

Ultra-high-resolution OCT precisely measures thin, transparent coating layers starting at a thickness of 1 µm and provides high-resolution 2D and 3D images for reliable quality control directly on the production line.

Custom OCT

We develop OCT systems that are precisely tailored to your needs – from needs assessment through integration into your production process to final validation

Already implemented: Case studies from industry and research

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Challenge

A manufacturer of high-quality printing and coating products faced the challenge of ensuring the quality of thin, transparent coating layers. Conventional testing methods, which relied solely on documented coating consumption, provided only average values and were unable to detect local variations in coating application. As a result, defective coatings were often detected too late, leading to scrap, rework, and increased testing effort.

Our Solution

We developed a high-resolution OCT system that precisely monitors the coating thickness of varnishes down to the range of one micrometer in a completely non-contact manner. The sensor system continuously measures the coating thickness and provides high-resolution measurement data. Specially developed software processes the collected data immediately and visualizes the results for the operator.

Result

  • Reduction in scrap due to immediate detection of uneven coating thicknesses
  • Complete quality documentation for every individual coating layer
  • Greater process reliability and improved reproducibility of the coating application
  • Smooth, uniform surfaces with enhanced product quality

© Fraunhofer IPT

Challenge

A sensor manufacturer faced the challenge of ensuring the quality of its aspheric microlenses. Existing inspection methods were unable to reliably verify all relevant characteristics at the required speed.

Our solution

In a feasibility study, we used optical coherence tomography (OCT) to inspect the microlenses non-destructively and efficiently. The major advantage: With just a single measurement, both the top and bottom surfaces of the lenses can be captured simultaneously. This allowed deviations and defects to be quickly identified without having to laboriously repeat the inspection process.

Result

  • Complete inspection of the top and bottom surfaces in a single measurement
  • Reliable detection of defects and deviations on the microlenses
  • Significantly reduced inspection effort and faster quality assurance
  • Foundation for efficient inline integration of OCT technology into production

biological cell isolated on whithe background microscope 3D Illustration
© virtua73/stock.adobe.com

Challenge

Three-dimensional cell cultures provide a much more accurate representation of the complex processes occurring in the human body than conventional two-dimensional models. This is a crucial advantage for drug research, as it allows active ingredients to be studied under more realistic conditions. However, 88 to 95 percent of all drugs fail in clinical trials because results from 2D cell cultures are not transferable. The precise visualization of 3D cell cultures is therefore one of the key challenges.

Our solution

To reliably visualize the structures and developments of 3D cell cultures, we rely on optical coherence tomography. This technology enables detailed, non-invasive analysis in real time, thereby offering new possibilities for drug discovery.

Result

Improved visualization provides a more realistic basis for evaluating drug candidates. This increases the likelihood that promising compounds will make it to market—while simultaneously reducing development times and costs.

You can find more details and examples in our white paper.

White paper – OCT for 3D cell culture visualization

In-situ-Prozessüberwachung mittels koaxialer Optischer Kohärenztomographie (OCT) im LMD-w-Prozess.

Challenge

A manufacturer of additively manufactured components uses wire-fed laser deposition welding for repair processes. Recurring problems included fluctuating weld bead quality, incorrect laser focus position, and insufficient process stability. Conventional end-of-line inspections detected quality deviations too late, resulting in scrap, rework, and increased inspection costs.

Our solution

The inline monitoring system, developed specifically at Fraunhofer IPT, ensures that welding processes run reliably and precisely at all times. It continuously records all relevant parameters – such as focus position, wire feed, and weld bead geometry – thereby laying the foundation for consistently high quality. This provides a complete picture of the ongoing process.

The central element is an optical sensor system that monitors the laser focal plane and the topography of the weld pool. In addition, high-speed image processing and thermal sensors analyze weld formation in real time. This allows deviations such as pores, interruptions, or weld overhangs to be detected immediately.

All sensor data is consolidated by specially developed software. It presents the information clearly, makes the process transparent to the operator, and responds automatically to quality deviations. Depending on the situation, parameters such as the laser focus or wire feed rate are adjusted – ensuring maximum precision and process reliability.

Result

  • Continuous monitoring and automatic correction of the laser focus plane
  • Real-time weld seam inspection: immediate detection and classification of quality deviations
  • Complete documentation of all process and quality data for traceability
  • Greater process stability and improved reproducibility of weld seams