3D machine vision in injection molding: efficiency and quality with Sentinel Vision and Zebra Technologies

How Sentinel Vision, in partnership with Zebra Technologies, elevated the inspection of injection-molded plastic parts to a new level.

As part of Sentinel Vision’s commitment to driving intelligent automation and quality assurance in industrial environments, in the injection-molded plastic parts production sector, we are pleased to share a success story in collaboration with Zebra, a globally renowned provider of machine vision solutions.

Challenge context

In a highly demanding environment, the mass production of plastic parts through injection molding faces several key challenges:

• Detecting defects (microcracks, inclusions, deformations) quickly and reliably;
• Covering the entire surface of the part (100% inspection or close to it);
• Ensuring that the inspection process does not become a production bottleneck;
• Integrating in a scalable way into the existing environment, with minimal downtime.

With its expertise in inspection automation and 3D vision, Sentinel Vision identified that the right integration of hardware and software could significantly enhance quality levels, efficiency, and industrial return.

The implemented solution

In partnership with Zebra Technologies, a 3D machine vision inline solution was designed and installed, providing full part coverage and an operator-friendly interface. The key elements included:

• 3D capture system to ensure complete coverage and defect detection across the entire surface
• Vision software (including machine learning / deep learning functions based on Zebra’s offering) that enabled high-precision anomaly detection
• Integration was seamless within the injection molding production process, with minimal disruption and scalable to other machines or lines.

Thanks to Sentinel Vision’s expertise in adapting technology to a customized production context, the solution delivered greater agility, reliability, and real-time visibility into the quality of the parts produced.

Tangible results and customer benefits

The solution delivered multiple operational and strategic benefits:

• Increased defect detection rate, with full coverage and an adaptive algorithm that reduces late rejections or undetected defects;
• Waste and rework reduction, since earlier and more precise detection lowers the costs associated with defective parts;
• Higher productivity, as inspection now flows at the same pace as production or faster, without becoming a bottleneck;
• Improved traceability and visibility, with inspection data captured and integrated into the production cycle, enabling continuous improvement.
• Scalable solution, designed to be replicated across other machines or lines with efficient, modular adaptation.

For the customer, a global supplier of injection-molded plastic parts, this technical advancement translated into a competitive advantage: superior quality, shorter response times, and a lower total cost of ownership for the inspection solution.

Why it makes sense for the B2B industry

In today’s industrial context, where automation, machine vision, and quality are key differentiators, this type of project demonstrates:

• that simply applying “cameras and software” is not enough, nor is allowing defects to go unnoticed;
• the importance of adapting the solution to the company’s specific process;
• that the right partner (such as Sentinel Vision), with expertise in 3D vision, injection molding, and production integration, makes all the difference;
• that choosing leading technologies (like those from Zebra Technologies) ensures reliability, scalability, and global support;
• that results are not only technical, they also impact ROI, reputation, and the ability to meet market-driven deadlines and quality standards.

Next steps and how we can help

If your company operates a production line for injection-molded parts, or in any other area where visual inspection (2D or 3D) is critical, Sentinel Vision can:

• assess your current inspection process;
• propose a tailored solution using top-tier hardware and software (such as Zebra Technologies solutions) combined with our expertise in vision and automation;
• support the integration, implementation, and scalability of the solution;
• provide ongoing support, data analysis, and continuous improvement to ensure the investment delivers real results.

We believe this success story reinforces our purpose and demonstrates how technology, partnership, and know-how come together to raise industrial quality. We are ready to collaborate with you.

If you would like more technical details, implementation studies, or to discuss your specific application, we would be happy to schedule a conversation.

Thank you very much for your trust in Sentinel Vision.