Meaning
Non-destructive X-ray tomographic inspection reconstructs three-dimensional internal spatial structures of molded plastic components at sub-micron resolution. Applying micro CT scanning enables quality engineers to inspect internal voids, weld line integrity, and glass fiber alignment without cutting samples. Conventional destructive cross-sectioning alters internal stress fields and distorts soft polymer features.
X-ray absorption attenuation maps quantify internal density variations and fiber orientation tensors throughout complex mold geometries.
Radiographic Imaging
A rotating sample holder exposes the plastic part to high-energy X-ray beams from multiple projection angles. Digital detectors record density differences based on atomic number variations between polymer matrices, void spaces, and inorganic fillers. Reconstruction algorithms process hundreds of two-dimensional radiographs into a fully volumetric dataset.
Contrast resolution distinguishes virgin polymer matrix regions from high-density additives and metallic contaminants.
Defect Analysis
Volumetric analysis quantifies internal gas porosity and shrink voids formed during cavity cooling. Fiber orientation mapping evaluates local alignment tensors near ribs, gates, and wall thickness transitions. Structural finite element models import actual scanned fiber distributions to predict mechanical failure points under load.
Comparison of scanned point clouds against CAD models reveals internal core shift and wall thickness variations.
Inspection Value
3D internal inspection accelerates tooling qualification and root-cause failure analysis for complex injection molded assemblies. Quantifying void distribution prevents field failures in pressure-retaining fluid components. Non-destructive volumetric mapping confirms structural integrity without destroying valuable prototype parts.
