PaintChecker Tube
So light that it can be mounted on any robot arm.
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A mobile, miniature master, ideal for delicate small parts.
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From choosing the right system to calibration, we'll answer all your questions.
PaintChecker Gun
The lightweight sensor reaches even tightest places.
PaintChecker Cube
Our miniature sensor is the top choice for rough coatings.
PaintChecker Cube
Miniaturization to the square. Fits in every line
PaintChecker Tube-HP
The tiny HP high-power sensor with extra "oomph".
How Much Could You Save in Your Coating Process?
Powder consumption, rework, scrap, oven usage, and quality issues often create costs that remain hidden in day-to-day production. Using your relevant process data, our profitability analysis helps you identify where costs can be reduced and valuable production capacity can be recovered. You will immediately receive:
- an initial estimate of your savings potential
- a visual overview of your main cost drivers
- a breakdown by material, capacity, and quality risks
Simply select the areas relevant to your process and enter the corresponding figures. Your initial analysis will be displayed immediately—before you provide any contact details.
Calculate Savings
From Initial Estimate to Detailed Analysis
The initial analysis highlights the areas with the greatest economic potential. For a more accurate assessment tailored to your specific process, you can request a detailed analysis.
Once you submit your contact details, a member of our sales team will contact you, review the information with you, and provide a refined analysis of your savings potential.
Request Detailed Analysis
All good things ...
come in threes. Our OptiSense portfolio proves that the best things usually come in threes. Whether industrial test systems, mobile measurement devices or services, our solutions are guaranteed to get to grips with any measurement task, no matter how demanding.
Defect Detection Through the Integration and Validation of AI-Based Multisensor Systems in Battery Cell Manufacturing
The goal of the project is to develop an innovative, AI-based thermographic-optical multisensor system for the reliable detection of surface and volumetric defects in the production of electrodes for lithium-ion batteries. Through the intelligent combination of active thermography and optical imaging, defects are to be identified early, precisely, and in real time.
Both physical and digitally synthesized defect samples are being developed and used to ensure robust validation of the system. For the first time, the methodology outlined in VDA Volume 5.3 is being applied to validate an AI-based multimodal imaging system in the electrode manufacturing of lithium-ion batteries. This sets a new standard for the validation of intelligent quality assurance systems in battery cell production.
OptiSense is contributing its many years of expertise in the field of active thermography to the project. The focus is not only on determining coating thickness, but also on developing a high-performance thermographic imaging system for real-time defect detection and analysis throughout the entire manufacturing process.
The intelligent integration of active thermography with optical inspection methods and AI-supported real-time analysis enables comprehensive process monitoring. This allows even hidden material and manufacturing defects to be detected early on, production processes to be optimized in a targeted manner, and the quality and efficiency of battery cell manufacturing to be sustainably improved—far beyond the capabilities of simple coating thickness measurement.
Project Overview
- Project Management Agency: Projektträger Jülich (PtJ)
- Funding Agency: Industrie.IN.NRW
- Grant Number: EFRE-20801409
- Duration: January 1, 2026 – December 31, 2028
Presentation at the JOT Coating and Powder Meeting 2025
While the opening session will focus on artificial intelligence (AI) with two exciting keynotes, the conference will wrap up with a look at coating defects and their causes along the process chain. Other key topics include process optimization and quality assurance, as well as useful peripherals. In addition, two parallel sessions on wet and powder coatings will highlight measurement technology, along with other topics. Dr. Fabian Gaußmann from the OptiSense development team will talk about the new mini coating thickness testing system for holes, pipes, and hollow parts at the JOT trade congress in Mannheim on October 22, 2025, from 10:00 to 10:30 a.m.
Successful trip to the USA by Jörg Mülleneisen with customer visits and presentation at ACA Coating Tech in Pittsburgh
Jörg Mülleneisen, OptiSense Sales Manager and experienced expert in coating thickness measurement, visited several customers during his two-week trip to the USA to hold personal discussions and strengthen existing partnerships.
Presentation at the renowned ACA Coating Tech Conference in Pittsburgh
During the ACA Coating Tech Conference in Pittsburgh, OptiSense Sales Manager Jörg Mülleneisen talked about a “Groundbreaking new coating thickness measurement method for extended surfaces and moving components”. His presentation was extremely well received by the specialist audience and industry experts. Mülleneisen presented innovative approaches and technological advances that could revolutionize coating thickness measurement. The response showed the great interest in new, efficient solutions for quality control in the coating industry.
Exhibition booth at the Detroit Auto Show with distributor Rhopoint USA
OptiSense presented its latest products and services at the DSCT Focus Show together with US distributor Rhopoint. The auto show offered both the opportunity for intensive discussions with existing customers and the chance to establish new business relationships. Jörg Mülleneisen could gain valuable insights into the US market, as well as forge important contacts and further expand international cooperation.
European Coating Show 2025 – OptiSense Coating Measurement Solutions
At ECS 2025, our distributor URAI will present a selection of our broad portfolio. Experience a combination of proven solutions and exciting OptiSense innovations - from pioneering new coating thickness measurement methods and state-of-the-art industrial measurement systems to feather-light, non-contact handheld devices, there is a perfect solution for every need. Visit our OptiSense distributor URAI in Hall 3C Stand 427.
European Coating Show 2025: Coating thickness measurement made by OptiSense
Are you looking for new solutions of your coating thickness check? Whether dry, wet or moving measurement: At the ECS, our distributor URAI will present the innovative, non-contact OptiSense solutions for mobile handheld measuring devices and industrial coating thickness testing systems. You can also discuss measurement technology trends and new technologies with industry leaders at ECS from March 25 to 27, 2025 in Nuremberg. Find out more from our OptiSense distributor URAI in Hall 3C Stand 427.
DSCT Focus Show on May 1, 2025 in Detroit
For almost 50 years, coating experts have gathered at the DSCT Focus Show in Detroit (USA) to discuss opportunities and challenges in the coatings industry. Together with US distributor Rhopoint Inc., OptiSense will present a new measuring method for coating thickness testing at the specialist forum on Thursday, May 1, 2025: The newly developed photothermal testing method allows endlessly long surfaces and moving objects to be checked without having to move along with the parts.
Use the leading forum to expand your network, exchange ideas and find out what quality control options the new OptiSense testing method offers you.
More distributors join the OptiSense family
Almost 30 selected distributors are now certified as OptiSense Approved Partners. OptiSense thus offers uniform quality and consistent standards for coating thickness testing worldwide. All these regional distribution partners are companies from the automation and surface technology sectors and support their customers locally. Two further Asian distributors have now qualified as OptiSense partners: H. P. Automation Pvt. Ltd from India and HERGENG Enterprise Co. Ltd from Taiwan.