X-ray inspection systems Manufacturers online

X-ray inspection systems use high-energy electromagnetic radiation to visualize the internal structures of an object without damaging it.

Typically, the beams range from 30-300 keV, depending on the thickness of the material and the desired resolution.
When X-rays pass through an object, they are attenuated to varying degrees depending on the density and thickness of the material. This produces an image or data set on a detector that allows conclusions to be drawn about internal features - e.g. cavities, cracks, inclusions, foreign particles or assembly errors.

Below you will find the functionality and types of X-ray inspection systems, their areas of application and their advantages:

How X-ray inspection systems work:

A typical system consists of:

1. X-ray source:
   Generates beams by accelerating electrons onto a target (usually tungsten).
   The energy of the rays determines penetration capability and image quality.
2. Detector:
   Modern detectors are usually digital flat panel detectors or line sensors.
   They convert radiation intensity into digital images.
   Higher resolution detectors enable the detection of very small defects.
3. Test object:
   The part to be inspected, e.g. an electronic component, a cast part, a weld seam or a food product.
4. Image processing and software:
   Complex algorithms analyze images automatically, e.g. for porosity analysis, dimensional measurement, foreign object detection, density distribution or 3D reconstruction.

Depending on the system, the inspection can be static or inline.

Types of X-ray inspection systems:

1. 2D X-ray inspection (radiography):
   The classic form. A single two-dimensional image shows the superimposed material distribution.
   Typical for fast inline inspections, e.g. foreign object detection in packaging lines or simple quality inspection of electronic assemblies.
2. CT systems (computed tomography):
   Here, the object is scanned from many angles.
   A three-dimensional volume model is created through computational reconstruction.
   Ideal for complex structures, dimensional analyses or detailed fault localization in cast parts or additively manufactured components.
3. Inline X-ray systems:
   Specialized for high throughput rates.
   They usually work automatically and are integrated into production lines.
   Frequently used in the food and electronics industries.
4. Micro- and nano-focus systems:
   For extremely high resolutions.
   Microfocus: Detection of very small defects in the micrometer range.
   Nanofocus: Even finer structures, e.g. conductor paths, bond connections or micro components.
5. Backscatter X-ray:
   Uses scattered radiation instead of transmitted radiation. Used primarily for security checks, e.g. on luggage or vehicles.

Areas of application for X-ray inspection systems:

1. Industry and manufacturing:
Inspection of cast and forged parts for pores, cracks and blowholes.
Inspection of weld seams.
Quality control of assembly processes in the automotive industry.
Analysis of additively manufactured metal components.
Measurement of internal geometries that are otherwise inaccessible.

2. Electronics:
Inspection of solder joints (especially BGA, QFN).
Detection of bridging, voids and delamination.
Inspection of printed circuit boards for short circuits and incorrect wiring.
Inspection of wire bonds, chips and sensors.

3. Food industry:
Foreign body detection (metal, glass, stone, high-density plastic).
checking fill levels and product shape.
Ensuring the integrity of packaging.

4. Medicine and pharmaceuticals:
Inspection of medical products such as syringes, implants, catheters.
Foreign body detection in pharmaceutical production.
Inspection of blister packs.

5. Security and transportation:
Baggage and cargo screening.
Detection of dangerous substances or concealed objects.
Vehicle and container inspection.

Advantages of X-ray inspection systems:

• Components remain completely intact - ideal for high-value or expensive components.
• Defects that are not visible from the outside can be precisely localized.
• Modern detectors allow even the smallest defects to be identified.
• X-ray systems can be seamlessly integrated into production lines, including automatic defect classification.
• From metal to plastic to organic material - almost all materials can be inspected.
• Early defect detection reduces rejects, improves quality and lowers complaint costs.
• Detailed measurements, material analyses and virtual sections are possible, which conventional methods cannot achieve.

Today, X-ray inspection systems are indispensable in industry, security, medicine and food production. Their ability to visualize internal structures non-destructively enables a high level of quality assurance, process optimization and safety. With advancing digitalization, better detectors and AI-supported image evaluation, they are becoming even more powerful and versatile.

Here you will find an overview of the most important points to consider when purchasing X-ray inspection systems:

Purchasing an X-ray inspection system is a strategic decision that has both technical and economic implications. Whether in electronics production, the food industry, metal processing or in safety-critical sectors, such systems have a significant influence on product quality, process stability, throughput and cost structure. The following overview provides a comprehensive overview of what needs to be considered in order to achieve the optimum balance between technical requirements, regulatory specifications and economic efficiency.

• The first step involves precisely defining the applications. This includes material types, part sizes, typical defects and the desired level of detail of the inspection.
• The parameters vary considerably depending on the industry.
• For electronic assemblies, for example, the focus is on displaying the finest structures and inspecting concealed solder joints.
• In the metal industry, the focus is on pores, cracks, blowholes and variations in wall thickness.
• In the food industry, the focus is on foreign body detection and packaging integrity.
• Equally important is the decision between random sample testing, laboratory analysis or continuous inline inspection.
• This basic needs analysis determines which system class is suitable.
• Depending on the requirements, a 2D system, a high-resolution microfocus system or a computer tomograph may be the better choice.
• Central aspects are:
• The resolution and focal spot size. The smaller the focal spot, the greater the level of detail.
• Systems with micro- or nanofocus technology are required for microstructures or solder joint inspections.
• Penetration power: Thick or very dense materials require higher voltages and powerful sources.
• For thin-walled objects, on the other hand, high voltages are unnecessary and are detrimental to image quality.
• 2D or 3D: This depends on the complexity of the components.
• CT is suitable when exact geometry measurements, material analyses or virtual sections are required.
• The detector is decisive for image sharpness, density contrast and speed.
• Important features are
• Pixel size and sensitivity: These determine the ability to detect small defects.
• Detector size: Relevant for large-area objects or high throughput requirements.
• Image processing software: Modern systems use automatic defect detection, learning algorithms, porosity analysis or measurement functions.
• The flexibility and accuracy of the software can determine the overall efficiency.
• In addition, the user interface should be intuitive, robust and easy to integrate into existing IT structures.
• Professional X-ray systems differ greatly in terms of ease of use and mechanical quality.
• Important points are
• Loading concept: Manual loading, automated feed mechanisms, roller conveyors or robot interfaces - depending on the production flow.
• Inspection chamber size: This determines which objects can be inspected and influences the subsequent flexibility.
• Positioning systems: High-quality axes, precise motors and repeatable movements increase image quality and reduce inspection times.
• Ergonomic operation: A well-designed workstation is crucial for continuous operation, including easy maintenance access, height-adjustable elements or automated inspection sequences.
• Seamless integration is particularly important in production lines.
• Key aspects here are
• Interfaces and communication: support for MES, ERP and quality management systems. Standardized interfaces such as OPC-UA simplify integration.
• Automation capability: Self-learning defect detection, automatic good/bad decision, logging and traceability are crucial for Industry 4.0 environments.
• Cycle time: In high-throughput lines, the system must deliver sufficient speed without compromising on image quality.
• X-ray inspection systems must meet strict legal requirements. These include:
• Shielding and leakage radiation: the system must be fully enclosed, CE-compliant and equipped with safety interlocks.
• Documentation requirements: Operating license, regular inspections, radiation safety officer or training certificates.
• Additional safety features: Emergency stop switch, tamper protection, automatic door monitoring and logging.
• Missing or unclear safety documents should be taken as a warning signal.
• An X-ray system is a long-term investment. In addition to the purchase price, running costs and service quality are decisive factors.
• The following must be taken into account:
• Availability of service personnel: A provider with fast response times reduces downtime risks.
• Spare parts supply: Long delivery times drastically increase downtimes.
• Calibration and maintenance contracts: Regular system checks ensure long-term image quality.
• Software updates and life cycle support: Technical developments should be accessible via updates.
• ROI consideration: Reduced waste, improved quality and minimized recall costs must be weighed against acquisition and operating costs.
• Flexibility for future requirements: A system that can be upgraded or retrofitted protects against technological obsolescence.

Purchasing an X-ray inspection system is much more than just choosing a suitable image resolution or penetration. Professional decisions take into account a complex interplay of technical requirements, process integration, software capability, radiation protection safety and long-term cost-effectiveness. Those who carefully analyze these aspects will end up with a system that not only reliably detects defects, but also increases efficiency, improves product quality and contributes to stable processes in the long term.

X-ray inspection systems can be purchased from various suppliers. Comprehensive information about manufacturers and suppliers of X-ray inspection systems from all over the world can be found on Exportpages.