Revolutionizing smartphone defect detection with Hybrid Data Cameras

Overview

Revolutionizing smartphone defect detection with Hybrid Data Cameras

Alt-text: Overview of smartphone critical inspection areas imaged by Mega Phase Camera

Caption: Comprehensive Coverage: High-precision imaging for all key smartphone quality areas

In the high-precision world of consumer electronics manufacturing, Mega Phase Technology’s Sizector® 3D Cameras and Hybrid Data Cameras have become the go-to solutions for industry leaders. From PCs and tablets to smartwatches and VR headsets, our technology covers critical production stages.

As we approach the peak season for new smartphone releases, manufacturers face increasing pressure to deliver flawless quality. Here is how our Hybrid Data Cameras are solving the toughest inspection challenges in mobile phone manufacturing.

Common pain points

Traditional inspection systems struggle with modern manufacturing demands:

A wide range of complex defect

Different defects appear in various locations, often requiring multiple stations for a single part. However, unified solutions capable of detecting all defect types are scarce.

Inconsistent result 

For nowadays high-mix production lines, standard imaging systems struggle to adapt to changes in product specification, color, and size (SKUs).

Low integration and scalability

Bulky, complex lighting rigs consume valuable production floor space and are difficult to replicate across lines.

The solution: Mega Phase 2.5D Hybrid Data Cameras

The Hybrid Data Camera is a premier visual inspection hardware featuring powerful real-time onboard processing of raw images. It directly outputs high-quality, information-rich 2D and 2.5D images.

With built-in imaging modes (photometric stereo and phase deflectometry), it is optimized for detecting defects across surfaces of various materials. By providing superior data, the camera significantly boosts AI training efficiency, helps users increase defect detection rates, shortens project deployment cycles, and reduces the overall cost of ownership.

able results.

Key advantages:

Data-dense output: Generates up to 40+ image layers to highlight specific defect types.

High integration: Replaces complex multi-angle lighting systems, equivalent to multiple traditional stations in one compact unit.

Extreme flexibility: One system can detect multiple defect types across different materials.

Application scenario 1: Photometric Stereo Mode

Best for: Diffuse reflection and some highly-reflective surfaces.

Equipped with Photometric Stereo, the DS/DH series detects surface irregularities like dents, pits, fine scratches, tool marks, edge chipping and contamination that 2D cameras often miss.

Case A: pressure sensitive adhesive (PSA) on smartphone middle frame

Alt-text: Photometric Stereo image by Mega Phase Hybrid Data Camera revealing invisible microscopic dents on pressure-sensitive adhesive on the smartphone middle frame

Caption: Invisible microscopic dents on mid-frame PSA, captured by DS/DH series

Performance: 150ms exposure time.

Efficiency: Images two units simultaneously.

Result: A single camera meets all inspection requirements. 19 selectable output channels allow for the precise detection of imprint marks, clamping marks, and other challenging defects in a single shot.

Case B: smartphone battery

Alt-text: High-precision Photometric Stereo imaging by Mega Phase Hybrid Data Camera, revealing minute scratches on a smartphone battery surface

Caption: DS/DH series clearly visualizes extremely fine scratches on battery surfaces

Precision: Detects micro-scratches as small as 0.04–0.05mm.

Flexibility: Adapts seamlessly to batteries of different colors and specifications.

Application scenario 2: Phase Deflectometry Mode

Best for: Specular, and transparent surfaces.

Equipped with Phase Deflectometry algorithm, the DM/DH series is ideal for highly reflective (specular) and transparent objects.

By adjusting pattern parameters, such as period, direction, and style, and analyzing the reflection, it effectively detects surface irregularities, micro-scratches, and tiny pits.

Case C: foldable smartphone screens

Application: Combined with programmable screen lighting to detect creases, pressure marks, and scratches on flexible displays.

Value: Solves the difficulty of inspecting transparent/black mirror surfaces.

Alt-text: Phase Deflectometry inspection image by Mega Phase Hybrid Data Camera, revealing fine surface defects on a smartphone flexible foldable screen

Caption: Invisible microscopic defects on a smartphone foldable screen, captured by DM/DH series

Case D: camera module brackets

Efficiency: Captures 9–12 units in just one shot.

Capability: Effectively detects deformation and flatness issues.

Alt-text: High-precision Photometric Stereo imaging by Mega Phase Hybrid Data Camera, revealing minute scratches on a smartphone battery surface.

Caption: DM/DH series clearly visualizes extremely tiny pits on battery surfaces.

Other info

The Hybrid Data Camera series is available in 8.1MP, 16.2MP, and 20MP resolutions. Ready to upgrade your inspection line? Contact us today for a project evaluation or to request a demo unit.