How Basler ace Cameras Enable Automated Inspection of Surgical Masks

Basler cameras and image processing software ensure seamless quality inspection that meets medical regulations

In this application, Basler ace cameras enable high-speed automated inspection of disposable face masks, improving defect detection, increasing throughput, and supporting compliance with medical quality standards. Automated inspection systems use machine vision cameras and image acquisition software to ensure product quality in medical and pharmaceutical manufacturing.

Using Basler ace camera in your automated inspection workflow ensures high-yield, high-quality production.
Using Basler ace camera in your automated inspection workflow ensures high-yield, high-quality production.

Why automated inspection is critical for disposable face mask manufacturing

Fueled by O-Net Technologies' commitment to automated industrial image processing, Basler worked with the company to develop a smart inspection system for surgical masks to automate lengthy, error-prone manual quality checks. The resulting fully automated visual inspection system increased throughput and ensured product conformity and reject detection.

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Automated visual inspection supports the overall quality of critical features on a surgical mask.
Automated visual inspection supports the overall quality of critical features on a surgical mask.

What’s the challenge when inspecting disposable face masks

Every part of a face mask must be tested during the production process to sort out defective masks. Within the inspection workflow, there are three key challenges:

  • Inconsistent gray-scale values from the grainy surface of the non-woven fabric

  • Environmental factors and randomized mask positioning as it moves through the conveyor belt

  • Low visual contrast and spatial overlap between mask features, limiting sensors when distinguishing the edge, ear loop, and metal strip

Resulting face mask size measurement using a machine vision system with Basler components.
Resulting face mask size measurement using a machine vision system with Basler components.

The solution: automated defect detection for surgical masks

Using customer-specific lighting and a  Basler ace camera with 5 MP resolution, the automated inspection system produced high-quality, accurate image data. The customer needed detailed imaging to meet the requirements of their alignment algorithm, which ensures that the masks meet regulatory standards.

With the high resolution integrated, the system seamlessly inspected:

  • The shape, edges, and size of the masks

  • The length and attachment points of the ear loops

  • The length and position of the nose wire

A key factor was the Basler ace camera, which improved the overall camera and system stability. This reduced maintenance and enabled the production process to run longer without interruption.

Ultimately, automating the inspection system and quality control process significantly increased the test rate compared to manual workflows.

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The advantages of using Basler’s imaging solutions for automated inspection systems

  • Faster and more secure quality inspection in accordance with standard regulations

  • Guaranteed camera stability, significantly reducing maintenance costs

  • Seamless system development using developer-friendly Basler pylon Software Suite

Products for smart inspection workflows

Have a similar inspection challenge? Work with Basler to automate your process.

Explore our Vision System Configurator
  • The Basler ace

    Basler ace area scan camera

    The ace camera is available with a diverse selection of sensors, resolutions, and speeds—all at a great value.

  • Basler machine vision illumination includes a wide range of lighting types, controllers, and accessories. All Basler products are carefully matched to ensure smooth interaction between all vision components.

    Machine vision lighting

    The right lighting is critical in a vision system. Properly combining lighting with the camera and lens ensures the best possible results in your application.

  • Fixed focal length and telecentric lens from Basler's extensive portfolio of Machine Vision Lenses

    2/3" lenses

    The fixed focal length lenses fit Basler cameras perfectly. We always offer the optimal lens for different vision requirements.

How can we support you?

We will be happy to advise you on product selection and find the right solution for your application.

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