Operating across two production facilities with four SMT lines, the customer manufactures complex PCB assemblies for customers in high-reliability sectors including medical, military and industrial electronics.
As part of a review of its inspection strategy, Esprit’s engineering team evaluated several inspection technologies available on the market. The process included a comparison of camera-based, laser-based and Moiré fringe-based inspection systems, with demonstrations and trials carried out using the same representative PCB assembly.
Rob Pembroke-Burn, Production Engineer at Esprit Electronics, said: “It was really great to get a chance to spearhead the technical review aspect of this investment, having lived and managed the challenges of our existing inspection processes. The breadth of and quality of technology and the advancements are eye opening. We knew that whichever unit we selected was going to be a step up for the company, but our job was to identify the best technology among the leading platforms.”
Following demonstrations conducted with Altus Group, the Koh Young Zenith 2 AOI system demonstrated clear advantages for Esprit’s complex PCB assemblies. The platform uses True 3D measurement technology based on Moiré interferometry, capturing precise height and volume measurements across the PCB surface rather than relying solely on two-dimensional image analysis. This approach enables accurate inspection of solder joints and components across complex PCB layouts while reducing the assumptions typically associated with conventional AOI systems.
Following further technical discussions and a subsequent review, Esprit confirmed its decision to invest in two Zenith 2 systems equipped with eight-megapixel imaging, Offline Programming (OLP) capability and the KSMART Pro software platform.
The Koh Young Zenith 2 platform combines high-resolution optics, advanced vision algorithms and multi-projection Moiré interferometry to generate detailed 3D inspection data across the entire PCB surface. The system also integrates Koh Young’s KSMART software environment, which enables manufacturers to analyse inspection data and apply statistical process control tools to support process monitoring and improvement.
Allan Hawkins, Production Engineer at Esprit Electronics, said: “What a good result! The team and I are really happy with the investment and the step up in our inspection capacity. We are excited about the impact the technology will have on our internal efficiencies and processes, but ultimately the quality we can ensure our customers receive.”
Altus Group worked closely with the Esprit Electronics throughout the evaluation process, supporting the assessment of inspection technologies and demonstrating how measurement-based 3D inspection can provide greater process visibility for complex electronics manufacturing.
