What Is FlawSense Technology and How Is It Transforming Surface Defect Detection?
As manufacturers strive to improve quality, minimize waste, and streamline operations, advanced inspection technologies have become mission-critical. One of the most exciting innovations in recent years is FlawSense™, a surface defect detection system developed by LaserLinc. Designed to provide 360-degree, real-time 3D surface profiling, FlawSense™ sets a new benchmark in high-speed, in-line quality control.
If your production process involves extrusions, cables, tubing, or any continuous product where surface integrity is essential, FlawSense™ may be the technology that revolutionizes your line.
This article answers the most common questions about FlawSense™, how it works, and what makes it a game-changer in industrial inspection.
What Is FlawSense™?
FlawSense™ is a cutting-edge, non-contact inspection system developed by LaserLinc to detect surface flaws in continuous products. Unlike traditional systems that rely on single-point sensors or vision-based spot inspection, FlawSense™ uses high-speed 3D laser profiling to scan the whole surface of the material in real time.
This approach ensures complete coverage and enables the detection of even the most minor surface anomalies — including scratches, lumps, dents, gouges, and pits. FlawSense™ gives manufacturers a full 360-degree view of the product surface and identifies flaw types by analyzing their size, shape, and profile depth.
To learn more about LaserLinc and its innovations in laser-based metrology, visit the company’s homepage at
How Does FlawSense™ Work?
At its core, FlawSense™ uses a series of high-resolution 2D laser line scanners to generate a 3D profile of the product surface as it passes through the inspection zone. These scanners are mounted in a circular or semi-circular array to capture every angle of the product’s exterior in real-time.
As the material moves along the production line, the laser sensors project beams across the surface and detect any variation that deviates from the expected shape. These variations are translated into 3D surface maps, which are then processed by intelligent software that flags flaws according to user-defined thresholds.
The result? Instant, comprehensive defect detection with precise location tracking, size classification, and alarm notifications — all without touching or altering the product.
What Types of Defects Can FlawSense™ Detect?
FlawSense™ is highly versatile and can identify surface defects that can impact product quality or safety. These include:
Scratches and scoring
Dents and depressions
Lumps and bulges
Pits, voids, or bubbles
Twisting or shape deformation
Weld seams or joint irregularities
This makes FlawSense™ especially valuable in industries like:
Medical device manufacturing, where catheter tubing and guidewires must meet tight visual and dimensional standards
Wire and cable production, where outer jacket quality impacts electrical insulation and safety
Automotive and aerospace extrusion, where aesthetic and performance standards are high
Plastic and rubber extrusion, where profile shape consistency is critical
How Is FlawSense™ Different from Other Inspection Systems?
Many conventional inspection systems rely on cameras or contact-based sensors that provide limited visibility or can miss intermittent flaws. FlawSense™ stands out due to several major differentiators:
Full 360-Degree Coverage – No more blind spots. Every surface of the product is scanned continuously.
3D Laser Profiling – High-resolution surface mapping allows precise identification of shape-based defects.
High-Speed Operation – Built for fast production lines, FlawSense™ processes data at real-time speeds.
Defect Classification – Not only does it detect defects, but it also classifies them by type, size, and severity.
Seamless Integration—FlawSense™ works with LaserLinc’s Total Vu™ HMI platform and other measurement systems to provide unified process control.
This unique combination of speed, precision, and total visibility makes FlawSense™ one of today's most advanced inspection systems.
For a deeper dive into the FlawSense™ announcement and technology overview, refer to the official press release here:
FlawSense™ 3-Dimensional Detection Technology.
What Are the Key Benefits of Implementing FlawSense™?
Integrating FlawSense™ into your process line brings immediate and long-term benefits beyond surface inspection.
Improved Product Quality: Defects are caught early — even before they can lead to downstream issues or customer complaints. By identifying each flaw's exact location and size, manufacturers can make faster, more accurate process adjustments.
Reduced Scrap and Reword: When defects are discovered after production, entire rolls, spools, or batches may need to be discarded. FlawSense™ allows immediate intervention, reducing material waste and saving on rework costs.
Real-Time Alerts and Process Visibility: Operators can receive real-time alarms, visual displays, and defect logs. This improves process awareness and allows for continuous process improvement based on data trends.
Better Compliance and Documentation: Many industries demand traceability and proof of quality for every component. FlawSense™ provides digital documentation and data logging for compliance audits and quality control reporting.
Flexible Integration: FlawSense™ works seamlessly with existing line configurations, is adaptable to different product shapes and sizes, and integrates easily into larger quality monitoring systems — especially those using LaserLinc's Total Vu™ software.
https://drive.google.com/file/d/1aYYW--p_USb0AUYvu3Ky5wtreAgObIy4/view?usp=drive_link
How Does FlawSense™ Support Continuous Improvement?
Modern manufacturers are under pressure to meet standards and continuously improve. FlawSense™ supports this effort with:
Trend analysis tools to identify recurring issues or patterns
Customizable dashboards for better operator feedback
Data export capabilities for reporting and further analysis
Connectivity with line controls for automated adjustments
By offering a continuous feedback loop, FlawSense™ empowers teams to reduce downtime, avoid defect drift, and refine upstream processes based on real-world conditions.
Can FlawSense™ Handle Complex Product Geometries?
Yes. One of the standout features of FlawSense™ is its ability to handle a wide range of product geometries. Whether your material is round, flat, irregularly shaped, or includes surface textures, FlawSense™ can be configured to provide complete surface inspection without compromising accuracy.
Its modular setup allows for customized sensor arrays that ensure optimal coverage and resolution for each unique product. This makes it suitable for everything from fine wire coatings to large-profile extrusions.
Visit the official LaserLinc website to learn more about how FlawSense™ and other advanced measurement systems work together to create complete quality solutions.
Final Thoughts: Is FlawSense™ Right for Your Line?
If your business involves continuous product manufacturing and surface integrity is critical, FlawSense™ is a technology worth serious consideration. It brings unprecedented visibility to your process, reduces waste, improves compliance, and helps ensure your product meets the highest quality standards.
More than just an inspection tool, FlawSense™ is a platform for improvement — delivering data, insight, and confidence in every product that leaves your line.
Backed by decades of metrology expertise, LaserLinc continues to lead in non-contact measurement and inspection. With FlawSense™, they are helping manufacturers shift from reactive quality control to proactive process management and making defect-free production a realistic, achievable goal.
If you're ready to upgrade your defect detection process and want to see how FlawSense™ can work in your operation, contact LaserLinc today to schedule a consultation or demo. It’s time to see your process in full resolution.
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