# AI Weld Monitoring — Detect Defects in Real-Time Source: https://www.therness.com/ Language: en Catch drift while the arc is still on. Our [welding cameras](https://www.therness.com/welding-camera/) and HeatCore software watch the weld pool live, flag porosity, lack-of-fusion risk and process drift, and keep a record of every weld as evidence for ISO 3834 and ISO 17635. [Book a demo](https://www.therness.com/#Contact) [Explore our products](https://www.therness.com/products/) HeatCore AI walkthrough · replay of a real lab recording, not live production [Scroll](https://www.therness.com/#Trusted-By) **100%**welds monitored **480 fps**weld-pool video **up to 25 kHz**current & voltage Official spin-off of Politecnico di Torino, backed by T4P. [![Politecnico di Torino logo](https://www.therness.com/assets/images/Logo_PoliTo_dal_2021_blu_1.png)](https://www.polito.it/) [![Politecnico di Torino Spin-off logo](https://www.therness.com/assets/images/LogoSpinoff_new.png)](https://www.polito.it/) ![T4P brand logo](https://www.therness.com/assets/images/2022_01_28_T4P_Logo_Positivo_d0_1.png) What we do ## Inspect every weld. Not just samples. Most welds are judged after they have cooled. Therness puts a camera on the torch, measures every frame and keeps a record of each weld. ![Live weld-pool analysis icon](https://www.therness.com/assets/images/smart_toy.svg) ### See HeatCore shows the weld pool and its numbers live — area, temperature, size, position — and raises an alarm when they leave your limits. ![Weld record and data export icon](https://www.therness.com/assets/images/bubble.svg) ### Record Every weld on record: replay it frame by frame, chart its metrics, export video, metrics and profiles. ![Verified evidence shield icon](https://www.therness.com/assets/images/verified_user.svg) ### Prove Measured evidence for ISO 3834, ISO 17635, ISO 5817 and EN 1090-2 files. Conformity assessment stays with your welding coordinator. Therness in numbers ## Weld monitoring at work in industry - **Over2,000**welds monitored in production - **Over16 km**of weld seam monitored in production - **Over230**hours of welding monitored in production - **Over15**systems, thermal cameras and software licences shipped - **Over4**pilot and integration projects in industry - **7**industrial sectors served - **5**years of R&D on thermography for welding, from Politecnico di Torino - **Over15**peer-reviewed scientific papers by the founding team ### Where we operate ![World map of where Therness operates. Europe — installed systems and projects: Italy and countries across Europe, including the United Kingdom. Italy — headquarters, installed systems and projects. Markets served: United States, Canada, United Arab Emirates, Saudi Arabia, India.](https://www.therness.com/assets/images/where-we-operate.svg?v=1d309aca84) - **Europe — installed systems and projects**Italy and countries across Europe, including the United Kingdom - **Italy — headquarters, installed systems and projects** - **Markets served**United States, Canada, United Arab Emirates, Saudi Arabia, India Markets served: countries we have received qualified enquiries from or sent quotes to. Countries, not cities. Projects and enquiries from over 10 countries on 3 continents ### Industries served - Railway - Automotive and vehicles - Metalworking and steel - Oil & gas and energy - Electronics - Thermoforming and plastics - Packaging Data as of October 2026 See it working ## HeatCore AI on a real lab weld The current HeatCore AI software in 1 min 35 s: live view, metrics, seam tracking, C-scan and the record of the weld. ![HeatCore AI software walkthrough on a recorded lab weld](https://i.ytimg.com/vi/uATfRalbfo8/maxresdefault.jpg) Screen recording of the current HeatCore AI software. The thermal footage is one real weld from our lab cell, replayed in the software — not live production. [More weld footage on the Therness YouTube channel](https://www.youtube.com/@ThernessSRL) [See HeatCore AI](https://www.therness.com/products/therness-heatcore-ai/) [Book a demo](https://www.therness.com/#Contact) Products ## One platform. Thermal, visual and electrical data. HeatCore software in three tiers, on four Therness sensors. Start with thermal monitoring and add visual, electrical and AI as your coverage grows. ![HeatCore AI weld monitoring — live thermal analysis on welding line](https://www.therness.com/assets/images/optimized/heatcore-action-v2.webp) Flagship HeatCore AI ### Inline thermography with defect AI Adds real-time defect classification and AI anomaly detection to the live thermal view, with Kaizen reports and a record for every seam. Runs on an edge server in your plant. **Real-time**defect classification **AI**anomaly detection **Edge**on-prem, no cloud **Record**per weld [Book a demo](https://www.therness.com/#Contact) [View HeatCore AI specs](https://www.therness.com/products/therness-heatcore-ai/) ![HeatCam thermal camera mounted next to the MIG torch on a robot arm, the HeatCore Basic set-up](https://www.therness.com/assets/images/optimized/heatcore-basic-heatcam-torch-600.webp) Entry tier #### HeatCore Basic Live thermal view, overheating alarms, basic SPC limits and an evidence log. Also for manual stations. Learn more → [HeatCore Basic](https://www.therness.com/products/therness-heatcore-basic/) ![Therness lab welding cell with HeatCore live weld monitoring on the screen beside the cell](https://www.therness.com/assets/images/optimized/heatcore-robotic-cell-live-ui-600.webp) Robotic cells #### HeatCore Robotic Turnkey package for robotic cells, reading the robot controller's signals through its API. Learn more → [HeatCore Robotic](https://www.therness.com/products/therness-heatcore-robotic/) ![HeatCam IR-C cylindrical thermal camera](https://www.therness.com/assets/images/optimized/heatcam-ir-c-render-600.webp) Thermal #### HeatCam IR-C 384 × 240 px radiometric camera, −20 to 900 °C standard (1500 °C optional), 60 mK NETD, PoE. Learn more → [HeatCam IR-C](https://www.therness.com/products/heatcam-ir-c/) ![HeatCam IR-S compact thermal camera](https://www.therness.com/assets/images/optimized/heatcam-ir-s-render-600.webp) Thermal, compact #### HeatCam IR-S Compact LWIR camera for additive cells and robot heads, 400…1600 °C (high-temperature version). Learn more → [HeatCam IR-S](https://www.therness.com/products/heatcam-ir-s/) ![PoolDrop high-speed weld-pool camera](https://www.therness.com/assets/images/optimized/pooldrop-render-600.webp) Visual #### PoolDrop Weld-pool video up to 480 frames/s, with Class 1 laser-safe light. USB 3.0. Learn more → [PoolDrop](https://www.therness.com/products/therness-pooldrop/) ![WeldTrace welding data acquisition unit](https://www.therness.com/assets/images/optimized/weldtrace-render-600.webp) Electrical #### WeldTrace Voltage, current and wire feed at up to 25 kHz, gas at 10 Hz, recorded with the thermal data in HeatCore. Learn more → [WeldTrace](https://www.therness.com/products/therness-weldtrace/) Building near-net-shape parts with wire-arc DED? The same HeatCam thermal sensors also drive our [layer-by-layer WAAM monitoring](https://www.therness.com/waam-additive-manufacturing-monitoring/) for large-format additive work. After the weld: [Therness ForgeSense](https://www.therness.com/products/therness-forgesense/) keeps a temperature record of the post-weld heat treatment (PWHT) for every piping joint. It is offered as a pilot. Need a thermal camera on its own? [HeatCam IR-C is in stock and ready to ship](https://www.therness.com/industrial-thermal-camera/) for maintenance, process control and R&D. [Explore all products](https://www.therness.com/products/) [Book a demo](https://www.therness.com/#Contact) Offers ## Consulting, WAAM parts, cameras and vision Beyond our monitoring systems: engineering on your process, parts made in our cell and cameras ready to ship. Price on request. Consulting #### Engineering consulting Feasibility studies, trials in our lab cell, integration on your line and ongoing support on welding, WAAM, thermography and vision. Request a quote → [Engineering consulting](https://www.therness.com/engineering-consulting/) Production #### WAAM contract manufacturing Parts and prototypes built in our cell, each shipped with its thermal record layer by layer. Request a quote → [WAAM contract manufacturing](https://www.therness.com/waam-contract-manufacturing/) In stock #### Industrial thermal camera HeatCam IR-C with brackets and Air Purge in stock, ready to ship once you confirm the order. Request a quote → [Industrial thermal camera](https://www.therness.com/industrial-thermal-camera/) Vision #### Machine vision systems Therness PoolDrop high-speed camera in stock or on monthly rental, and custom vision systems for cells and lines. Request a quote → [Machine vision systems](https://www.therness.com/machine-vision-systems/) Services ## Engineering around the system Our engineers work on your parts, from the first feasibility check to the last cell. Before you buy #### Feasibility & welding trials A feasibility analysis and welding trials on your parts in our lab cell, before you commit to a line. Learn more → [Feasibility & welding trials](https://www.therness.com/welding-engineering-services/) On your line #### Design, installation & integration System design, installation, PLC and software integration, documentation, commissioning training and remote support. Learn more → [Design, installation & integration](https://www.therness.com/services/) Process #### Welding process consulting Ongoing technical consulting on parameters, procedures and the data your cells record. Learn more → [Welding process consulting](https://www.therness.com/services/welding-process-consulting/) Plant #### Industrial thermography Thermographic inspections of plant and equipment, with a prioritised report of the thermal anomalies found. Learn more → [Industrial thermography](https://www.therness.com/services/industrial-thermography/) ## Find your setup in up to seven questions Answer a few questions about your process and get the Therness camera, HeatCore tier or WeldTrace setup that fits, with the matching documents and videos by email. [Start the Solution Finder](https://www.therness.com/solution-finder/) Inspect Every Weld. Not Just Samples. ## Traditional inspection vs AI monitoring Before ### Traditional inspection - Sample-based inspections - Complex and time-consuming audits - Operator dependency - Rework - Limited process control After ### AI monitoring - Real-time detection - 100% weld monitoring - Scalable across production lines and plants - Simplified audits and full traceability - Fewer returns and rework Fresh from the line ## Latest weld monitoring videos New high-speed and thermal footage from real welding cells — weld pool, droplet transfer, and WAAM, straight off our cameras. PoolDrop ![Weld pool at 480 fps, thermal image and welding current, recorded during the same bead](https://i.ytimg.com/vi/GO0_S_iapdA/mqdefault.jpg) ### [Weld pool at 480 fps, thermal image and welding current, recorded during the same bead](https://www.therness.com/videos/three-sensors-same-weld-bead/) Three recordings of the same bead from our robotic R&D cell: PoolDrop films the weld pool at 480 fps, HeatCam records the temperature field at 25 fps and WeldTrace samples the welding current at up to 25 kHz. Real footage, no generated frames. [High-speed welding camera →](https://www.therness.com/welding-camera/) PoolDrop ![CMT welding at 480 fps — every droplet visible](https://i.ytimg.com/vi/JaUdmxM_t7E/mqdefault.jpg) ### [CMT welding at 480 fps — every droplet visible](https://www.therness.com/videos/cmt-480fps-every-droplet/) Cold Metal Transfer at 480 fps in landscape: the wire dips into the pool and retracts, releasing one clean droplet per cycle — low heat input, near-zero spatter, arc glare filtered out. [High-speed welding camera →](https://www.therness.com/welding-camera/) WAAM ![Wire-arc deposition with ER70S wire, cell and close-up](https://i.ytimg.com/vi/Ig-mX0SjFJU/mqdefault.jpg) ### [Wire-arc deposition with ER70S wire, cell and close-up](https://www.therness.com/videos/waam-gear-tooth-wire-arc-additive/) A 15-second vertical clip of MAG wire-arc deposition with 1.2 mm ER70S wire: first the torch in the cell, then a close-up camera following the torch and the melt pool along the bead. [WAAM additive monitoring →](https://www.therness.com/waam-additive-manufacturing-monitoring/) HeatCore ![Burn-through under a high-speed camera](https://i.ytimg.com/vi/cgDHtE6hg7s/mqdefault.jpg) ### [Burn-through under a high-speed camera](https://www.therness.com/videos/welding-burn-through-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 →](https://www.therness.com/welding-camera/) [Browse all videos](https://www.therness.com/videos/) How we work ## Start with one cell, scale on evidence Four steps, each closed on data from your own parts. Measured, not promised. 01 ![Therness thermal weld-monitoring camera and air-purge nozzle mounted on a welding line over a steel groove joint](https://www.therness.com/assets/images/optimized/thermalcamera_and_airpurge_mounted.webp) ### Pilot HeatCam and HeatCore in one cell, on your own parts. The equipment is also available on monthly rental for the pilot. Plan a pilot → [Pilot](https://www.therness.com/welding-engineering-services/) 02 ![Two thermal C-scans of weld seams in false colour: a reference weld and a weld whose joint is misaligned](https://www.therness.com/assets/images/optimized/cscan-reference-vs-misaligned-800.webp) ### Validate Compare our records with your inspection results on the same welds. How we validate → [Validate](https://www.therness.com/weld-monitoring-validation/) 03 ![HeatCore live view while recording: thermal image of the torch and weld pool on a plate beside the area, temperature, dimension and centroid trends](https://www.therness.com/assets/images/optimized/heatcore-live-plate-pool-metrics-800.webp) ### Set the limits Agree the acceptance criteria with your quality team before you scale. See the weld monitoring system → [Set the limits](https://www.therness.com/welding-monitoring-system/) 04 ![Therness lab welding cell with HeatCore live weld monitoring on the screen beside the cell](https://www.therness.com/assets/images/optimized/heatcore-robotic-cell-live-ui-1200.webp) ### Roll out The same criteria on each cell, and a record for every weld. Scale with HeatCore AI → [Roll out](https://www.therness.com/products/therness-heatcore-ai/) FAQ ## Weld monitoring FAQs Quick answers for engineers and quality teams evaluating inline weld monitoring, thermography, and compliance evidence. ### 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 to [thermographic weld inspection and NDT testing](https://www.therness.com/thermography-ndt-testing/). ### How long does installation and setup take? We start with a pilot in one cell on your own parts, compare our records with your inspection results, agree the acceptance criteria and then roll the same criteria out cell by cell. To scope your line, [talk to an expert](https://www.therness.com/contact/). ### Can you integrate with our QMS or PPAP/CAPA workflows? Yes. HeatCore AI exports CSV and reports for every job and offers a REST API (OpenAPI 3.1 schema) and WebSocket; bidirectional PLC integration is set up on project with your IT team, so weld records and alarms can feed your quality workflows. ### What ROI should we expect? ROI depends on scrap/rework cost, throughput and defect rate. Request a detailed ROI analysis on the [contact page](https://www.therness.com/contact/). Proof, not promises ## What our cameras and software show Recordings from our lab cell, live demos at trade shows and the Therness cameras themselves. ![Therness engineer presenting weld monitoring to visitors at an automation trade-show stand, with a laptop and a tablet on the counter](https://www.therness.com/assets/images/optimized/casa-ia-cim40-automation-testing.webp) Live demo at a trade show ![HeatCore AI live thermal view: weld pool segmented in red, a measurement line across the pool and the temperature scale](https://www.therness.com/assets/images/optimized/heatcore-live-pool-segmentation-roi-800.webp) Live weld-pool thermal analysis ![HeatCore live view while recording: thermal image of the torch and weld pool on a plate beside the area, temperature, dimension and centroid trends](https://www.therness.com/assets/images/optimized/heatcore-live-plate-pool-metrics-800.webp) Live metrics while recording ![Two thermal C-scans of weld seams in false colour: a reference weld on the left; on the right, the bright edge streaks bend where the joint is misaligned (hi-lo)](https://www.therness.com/assets/images/optimized/cscan-reference-vs-misaligned-800.webp) Misaligned joint on a thermal C-scan ![Therness HeatCam IR-C stainless-steel infrared thermal camera on a mounting bracket for inline weld monitoring](https://www.therness.com/assets/images/optimized/heatcam-ir-c-product-v2.webp) HeatCam IR-C thermal camera ![High-speed PoolDrop camera frame of a molten weld pool and electrode showing real-time weld-pool dynamics](https://www.therness.com/assets/images/optimized/pooldrop-pool-photo.webp) 480 fps weld-pool capture Buyer's guides ## Featured weld-monitoring guides Evaluating cameras, monitoring systems or robotic-cell integration? Start with these in-depth guides from our engineers. Cameras ### How to choose a welding camera in 2026 Sensor types, frame rates and the specs that actually matter when you compare welding cameras. Read the guide → [How to choose a welding camera in 2026](https://www.therness.com/blog/welding-camera-buyers-guide-2026-what-to-look-for/) Systems ### Picking a weld monitoring system Thermal, machine-vision and acoustic sensing compared — how to match a system to your line. Compare approaches → [Picking a weld monitoring system](https://www.therness.com/blog/welding-monitoring-system-buyers-guide-thermal-vision-acoustic/) Fundamentals ### Weld quality monitoring 101 How real-time AI catches porosity and lack of fusion while the arc is still running. Learn the basics → [Weld quality monitoring 101](https://www.therness.com/blog/weld-quality-monitoring-101-real-time-ai/) Integration ### Cameras for robotic welding cells A practical playbook for adding vision to robotic welding cells without losing uptime. See the playbook → [Cameras for robotic welding cells](https://www.therness.com/blog/camera-for-robotic-welding-cells-integration-guide-2026/) [Read more guides](https://www.therness.com/blog/) ## Let’s Talk Quick question or ready for a demo? Drop us a message and we’ll get back to you within 24 hours. Contacts ## Still have doubts? Contact us! Have questions or need more details? Reach out to us—we're ready to support your journey toward smarter welding. ![Email icon](https://www.therness.com/assets/images/mail.svg) ### Email Speak directly with our team for quick assistance and expert guidance. info@therness.com ![Phone icon](https://www.therness.com/assets/images/call.svg) ### Phone Drop us a message, and we'll get back to you as soon as possible. +39 011 2424158 ![Location icon](https://www.therness.com/assets/images/location_on.svg) ### Headquarters Visit us and see how Therness is shaping the future of welding. [Corso Castelfidardo 30/A, Torino](https://www.google.com/maps/place/Corso+Castelfidardo,+30%2FA,+10129+Torino+TO/@45.0654936,7.6576068,1099m/data=!3m2!1e3!4b1!4m6!3m5!1s0x47886d1965577dab:0x89d28fe1219b2e59!8m2!3d45.0654936!4d7.6601817!16s%2Fg%2F11j8gphsfm?entry=ttu&g_ep=EgoyMDI1MDMyNC4wIKXMDSoASAFQAw%3D%3D)