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Applications

Material Intelligence for Advanced Manufacturing

Material properties shape both the product and the process that makes it, yet most are checked too late to act on. Manufacturers pay for that in scrap, slow ramps and late failures. PlasmaSens gives them a direct view of the material while there is still time to act.

Power Generation

Power Generation

Reads the coatings and functional layers in turbines, fuel cells and solar cells, where thickness, bonding and uniformity decide life and efficiency.

Aerospace

Aerospace & Defense

Characterizes hardened alloys, coatings, welds and joins on flight-critical parts.

Energy Storage

Energy Storage

Measures mass loading, porosity, resistivity, metal contamination and more on battery electrodes.

Semiconductor

Semiconductor

Characterizes thin films, coatings, and crystalline substrates that determine yield and performance.

Automotive

Automotive

Verifies coatings and alloys on powertrain, engine and EV components.

Electronics

Electronics and Displays

Characterizes coatings and multilayer films on flexible substrates.

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Application Examples Across Industries

A subset of the applications and industries where PlasmaSens has been demonstrated.

Applications Across Industries

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Industry

Energy Storage

PlasmaSens measures electrode coatings, slurries, separators and interface layers across the battery line non-destructively, so drift is caught before cells are built.

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Industry

Aerospace & Defense

PlasmaSens inspects coatings and alloys on flight-critical parts non-destructively, revealing coating thickness, microstructure and defects in a single scan.

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Industry

Power Generation

PlasmaSens reads the coatings and functional layers in turbines, fuel cells and solar cells non-destructively, where thickness, bonding and uniformity decide life and efficiency.

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Industry

Semiconductor

PlasmaSens characterizes thin films, doped layers and packaging materials non-destructively, without touching the wafer or die.

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Industry

Automotive

PlasmaSens verifies coatings on powertrain and EV components non-destructively, reducing the need for cut-and-polish checks.

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Industry

Electronics and Displays

PlasmaSens characterizes the polymer films, organic layers and thin-film stacks used in haptics, displays and chips non-destructively, from one scan per location.

Use Cases

Across the Product Lifecycle, from Lab to Line to Field

One platform answers a different question at each stage of a product’s life, from first development to parts returning from service. Today those answers come from separate tools, or from the same overloaded lab.

01R&D and product development02Supplier qualification and incoming inspection03Process and manufacturing engineering04Quality labs and failure analysis05Repair and overhaul (field)

01 · R&D and product development

Which material gives us the performance we want?

  • Scan in minutes, sample not destroyed
  • More candidate materials measured per day
  • Results in minutes, not the day or weeks that cutting, mounting and curing can take
  • Design of experiments at process speed, not lab-queue speed
R&D and product development

02 · Supplier qualification and incoming inspection

Is the material we received what we qualified?

  • Lot scanned against the qualified reference
  • Off-spec lots caught before they reach production
Supplier qualification and incoming inspection

03 · Process and manufacturing engineering

What is our process actually doing to the material?

  • Several properties from one scan, same location
  • See a process change move multiple properties at once
  • Process drift spotted as properties shift over time
Process and manufacturing engineering

04 · Quality labs and failure analysis

When something fails, why did it fail?

  • Earlier scans checked for anomalies that were present before the failure
  • Points teams toward the process step or equipment behind a failure
Quality labs and failure analysis

05 · Repair and overhaul (field)

Is this part still fit for service?

  • Designed to map coating condition on returned parts
  • The confidence to return a part to service instead of a full refurbishment
Repair and overhaul (field)
Featured article

What the Coating Line Doesn’t Tell You

Battery cell yield is largely decided before cell formation begins. A closer look at why, and what a better measurement strategy looks like.

Read the full story