Insight Ultrasonics :Advancing Automotive Weld Testing

Automobiles rely on thousands of spot welds to hold their structures together, making weld integrity critical to both safety and performance. Insight Ultrasonics is transforming weld testing with precision robotics. Its automated ultrasonic system combines phased array imaging, machine learning and robotic automation to give Tier 1 suppliers and OEMs a safer, faster and more reliable way to validate weld quality.

Destructive testing has long been the gold standard, but it is one of the leading causes of lost-time accidents in factories and creates unnecessary cost. Every destroyed part represents scrap losses, labor costs and missed sales opportunities, adding up to tens of thousands of dollars each month even at small sample sizes. Manual ultrasonic testing offers a safer approach, but it struggles to scale across the 6,000 spot welds in a typical vehicle.

“Our technology takes a dangerous, expensive process off the table and turns it into something safer and far more reliable,” says David Burks, managing partner and CEO.

Safer, Smarter Weld Validation

The platform begins the testing process with quick programming of weld counts, sheet thickness and materials, which are ingested into the system in minutes. The system includes a destructive testing entry screen for direct comparison during correlation, helping OEMs confirm accuracy before full deployment. Once validated, robotic probes use modern vision and ultrasonic imaging to precisely center themselves on each weld. Phased array sound pulses then map thickness and fusion with high resolution, while the system captures both photographic and ultrasonic imagery for full documentation.

Machine learning adds predictive capability by identifying weld patterns linked to failure criteria. When weld processes begin to drift, whether from worn tips, current variations or equipment changes, the platform issues early alerts. Maintenance can then be scheduled proactively, preventing bad parts before they appear on the line.

The benefits are evident in customer deployments. One Tier 1 supplier previously destroyed ten parts daily, each with nearly 30 welds, losing about $20,000 per month in scrap and labor. With Insight Ultrasonics, destructive testing was virtually eliminated, correlation accuracy reached 95 percent, OEM approval was achieved and the system paid for itself in under a year.

Another supplier in Michigan saw its first cell pay back at just 20 percent utilization, then added a second system designed for 12 part variations and up to 250 welds per part. At 50–60 percent utilization, this larger installation is expected to achieve ROI in less than nine months.

Scaling Reliability across Production

Every Insight Ultrasonics system is tailored to customer requirements, beginning with a consultative scoping process that evaluates part size, production volume, robot reach and safety requirements. Custom fixtures and rotators are designed to hold parts securely, while lighting and safety measures are adapted to each environment. Some manufacturers use collaborative robots for lighter assemblies, while others require full-size robots with safety curtains for larger production lines.

While highly customizable, most systems share common hardware and software modules, making them extensible without reinventing each solution. Integrators assemble the test cells, and Insight’s team trains operators and validates readiness. Skilled weld technicians, once tasked with dangerous destructive testing, can now be redeployed to higher-value work.

To overcome budget barriers, the company also offers leasing and robotics-as-a-service models. These options allow customers to spread costs over five years, avoid large upfront investments and begin saving immediately from operational budgets.

For Tier 1 suppliers and OEMs under relentless pressure to improve performance while reducing costs, Insight Ultrasonics is redefining weld validation, setting a new safety and efficiency standard across automotive production.