An impulse for a new development emerged from a networking event last year: Over several months, following extensive hardware research, ID Engineering developed a precise solution to detect even the smallest surface defects in vehicle production.

Stereophotometry and synthetic data

Stereophotometry and synthetic data

The ID specialists have developed a new solution in quality assurance: the combination of synthetic data generation, digital twins, and classical image processing. (Photo © ID GmbH)

ID Engineering has developed a new solution to meet the high quality requirements in vehicle production. What initially sounds simple—detecting tiny pimples and dents on body parts—becomes a real challenge in practice. Interfering contours, color differences, or even dust and dirt significantly hinder detection. After an extensive search for a solution, it became clear: stereophotometry provides the required precision.

Taking into account the wide variety of components and models from vehicle manufacturers

The solution lies in the combination of synthetic data generation, digital twins, and classical image processing. ID has developed its own light simulation model that realistically maps stereophotometry from different camera perspectives. This means camera and lighting angles can be simulated without an elaborate laboratory setup.

The advantages:

  • Ideal parameters are identified within a very short time to detect even the smallest surface deviations.
  • shorter development time
  • lower costs
  • Increased robustness of the subsequent production solution

The technology developed by ID has already been successfully presented at an innovation event hosted by a major automotive manufacturer.

Promising prospects for 2026

The next phase has already begun. ID Engineering is further developing the system so that the light simulation model can also be used in full motion on a conveyor belt. This paves the way for even more precise and efficient quality inspection in vehicle production. In addition, the solution is modular in design and can be flexibly transferred, from a technological standpoint, to other industrial use cases and production environments.

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