PolyU has developed “IntraSpect™”, a third-generation intelligent in-situ laser melt pool monitoring technology that marks a breakthrough in high-end precision manufacturing. During welding, high-energy heat sources melt metal to form a micro-scale molten zone known as the melt pool. Its internal condition directly affects welding quality, yet conventional technologies are unable to monitor it in real time during processing. By combining Optical Coherence Tomography with a multi-modal artificial intelligence engine, IntraSpect™ creates an “Industrial Eye” capable of monitoring the melt pool’s internal condition in real time with micron-level precision, capturing three-dimensional morphological changes during welding to address the long-standing industry challenge of welding defects at source. The project has established partnerships with multiple industry leaders in the Greater Bay Area and is advancing commercialisation, with potential applications extending to medical devices, aviation, aerospace and other sectors demanding exceptionally high welding quality.
The IntraSpect™ project is led by Prof. H.C. MAN, Founding Director of Research Institute for Advanced Manufacturing (RIAM), Dean of Faculty of Engineering, Cheng Yick-chi Chair Professor in Manufacturing Engineering and Chair Professor of Materials Engineering; and Prof. WEN Xiewen, Member of RIAM, Assistant Professor of Department of Industrial and Systems Engineering. Prof. Man has devoted forty years to the field of high-power laser welding, accumulating extensive industry collaboration experience and a deep understanding of industry pain points and practical needs while Prof. Wen specialises in precision optical instrument design and micro-scale dynamic capture technology. Their interdisciplinary collaboration and complementary expertise have ensured that the development of IntraSpect™ has been closely aligned with industrial application scenarios from inception.
Testing has validated that the IntraSpect™ system’s detection data deviates by less than two percent from destructive testing results, with technical specifications reaching internationally leading standards. Compared to similar imported products, the system costs approximately half as much, with investment recoverable in less than one year. The team estimates that this technology can replace up to 70% of destructive testing processes, substantially saving material and time costs while achieving 100% comprehensive monitoring and establishing a complete quality traceability record for every weld.
IntraSpect™ will initially focus on precision welding processes for new energy vehicle batteries and 3C electronic products such as smartphones. The team is collaborating with industry partners on pilot testing to transform the technology into practical industrial solutions. In the long term, the technology has additional potential for extension to medical devices, aviation, aerospace and other sectors with extremely stringent welding quality requirements.
The team aspires to combine Hong Kong’s research strengths with the Greater Bay Area’s industrial ecosystem to build a safer, more efficient and more intelligent high-end manufacturing system for the Nation, while injecting new momentum into Hong Kong’s high-quality economic development.
Press release: https://polyu.me/4kpXmBo
Online coverage:
Mirage - https://polyu.me/4r9KMZP
Hong Kong Economic Times - https://polyu.me/4tJuyIy
Bastille Post - https://polyu.me/4anKRSt
| Research Units | Research Institute for Advanced Manufacturing |
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