Injection-molded appearance defects span geometric (flash, sink) and visual (color, flow marks) types, shifting with mold, material lot and color. Rather than coding rules per defect, let the model learn what good looks like and catch every deviation in one pass.
An injection-molding plant supplies housings and structural parts for appliances, consumer electronics and household goods, with hundreds of molds and multiple colors and material lots per product. Common appearance defects include flash, sink marks, shrinkage, flow marks, silver streaks, color variation, black specks and contamination; defect forms fluctuate with process parameters, and manual inspection is subjective with hard-to-unify standards—color judgment especially leans on individual experience.
The plant faces the classic high-mix, low-volume bind: molds and colors switch frequently, and defect samples are hard to collect fully for every combination; conventional vision codes a rule per defect and must be retuned for every mold swap, with maintenance cost so high it cannot keep pace with changeover.
DaoAI solution: good-sample baseline plus APDT positive-sample learning for one-pass multi-defect detection
DaoAI combines a good-sample baseline with APDT positive-sample learning, using a few good samples to set the inspection standard for each mold/color combination; the system identifies flash, sink, flow marks and color variation uniformly in one flow, without enumerating samples per defect. Changeover simply recalls the matching combination's good-sample baseline.
- APDT positive-sample learning models from a few good samples, covering flash, sink, flow marks, silver streaks, color variation and black specks
- Geometric and visual defects are identified in one unified flow, with standardized, reproducible color judgment
- 5-minute zero-code changeover lets line operators switch mold/color on site
- Inspection baselines archived by mold and color, so high-mix small batches go live fast
However many molds and colors, there is one standard: does it look like a good sample of this combination.
After deployment, injection-molded appearance inspection moved from individual experience to a unified, reproducible standard, giving contentious defects like color variation and sink marks an objective verdict. Changeover became a 5-minute zero-code switch, hundreds of molds and many color combinations go live fast, misses and false calls fell together, and the line holds stable appearance quality across high-mix, small batches.