AI Weld Monitoring — Detect Defects in Real-Time
Stop scrap before it happens. Our welding cameras and AI flag porosity, lack of fusion and process drift live on the line — with ISO 17635 / 3834 evidence generated automatically.
Born at Politecnico di Torino — official spin-off of Italy's top technical university, backed by T4P.
Inspect every weld. Not just samples.
Detect
Real-time AI flags porosity, lack of fusion and anomalies — no manual review required.
Prove
Pre-set acceptance criteria and auto-logged evidence keep you audit-ready for ISO 3834.
Scale
One platform manages weld quality across robotic lines and global plants.
One platform. Thermal, visual, and AI.
Inline thermography with defect AI
Bolts onto robotic cells, captures the weld pool at 60 FPS, and classifies which welds pass, which fail, and why — with an evidence pack for every seam.
PoolDrop
High-definition, high-frequency weld-pool imaging — up to 480 fps.
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HeatCam IR-S
Compact square thermal camera for WAAM and robotic-cell integration. 384 × 240 px, 60 mK NETD.
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HeatCam IR-C
Cylindrical thermal sensor for induction pipe welding and confined-space applications.
Learn more →Traditional inspection vs AI monitoring
Traditional inspection
- Sample-based inspections
- Complex and time-consuming audits
- Operator dependency
- Rework
- Limited process control
AI monitoring
- Real-time detection
- 100% weld monitoring
- Scalable across production lines and plants
- Simplified audits and full traceability
- Fewer returns and rework
Latest weld monitoring videos
Every droplet visible — CMT welding at 480 fps
Vertical 480 fps short: every droplet detaching in a Cold Metal Transfer arc, with the weld pool and solidification front resolved frame by frame and arc glare filtered out.
High-speed welding camera →
Wire-arc additive manufacturing of a gear tooth
A gear tooth grown layer by layer with wire-arc additive manufacturing (WAAM) — a high-speed view of the deposition and melt pool that in-situ thermal monitoring tracks for layer consistency.
WAAM additive monitoring →
CMT droplet transfer — PoolDrop Cam Short at 480 fps
Quick vertical clip: Cold Metal Transfer welding filmed at 480fps with the PoolDrop Cam — droplet transfer and melt pool with arc glare filtered out.
High-speed welding camera →
Burn-through under a high-speed camera
The exact moment a weld pool collapses on a tee joint — burn-through captured frame by frame, and how real-time monitoring catches the precursor.
High-speed welding camera →AI NDT Agent — Procedures in Seconds
Instant Procedure Drafts
Receive a structured procedure with scope, equipment, calibration, and acceptance criteria.
Standards-Ready
Aligns to ISO, ASME, EN, and AWS references for faster Level III review.
Expert Follow-Up
Leave your contact and our thermography specialists follow up with tailored guidance.
From Installation to Real-Time Quality
Install
Mount thermal and visual sensors on your line with no downtime — plug-and-play with major robotic brands.
Explore thermography NDT testing →
Calibrate
Align thresholds and AI models to your specific materials and process in hours, not weeks.
See the AI weld monitoring system →
Scale
Get live alerts and ISO-ready evidence for every weld, synchronized across all your production cells.
Scale with HeatCore AI →Weld monitoring FAQs
Does Therness replace traditional NDT (UT/RT/PT/MT)?
It reduces defects by catching issues in-process and creates traceable evidence for every seam, but your final inspection plan depends on risk, customer requirements, and applicable standards. Many teams use Therness to prevent defects and to support ISO 17635 / ISO 3834 documentation.
What defects can you detect with AI weld monitoring?
We flag thermal/anomaly patterns correlated with porosity, lack of fusion risk, overheating and process drift. Coverage depends on your material, geometry and how we set acceptance criteria.
How does active thermography help weld inspection?
Active thermography measures thermal response to controlled excitation and highlights subsurface-related anomalies earlier than visual inspection. See the full guide at Active Thermography for NDT.
How long does installation and setup take?
Typical deployments start with a pilot cell: mount sensors, calibrate optics, align thresholds and train models on your production reality. To scope your line, talk to an expert.
Can you integrate with our QMS or PPAP/CAPA workflows?
Yes. Evidence packs and decisions can feed quality workflows and audits via API integrations with your existing QMS.
What ROI should we expect?
ROI depends on scrap/rework cost, throughput and defect rate. Request a detailed ROI analysis on the contact page.
Therness AI weld monitoring in the field
Let’s Talk
Still have doubts? Contact us!
Headquarters
Visit us and see how Therness is shaping the future of welding.
Corso Castelfidardo 30/A, Torino