Real Time Weld Defect Detection is becoming one of the most impactful breakthroughs in welding quality control. Sonibel Instruments has released a new sensor technology that detects weld defects as they happen, giving fabricators a way to catch issues early, reduce rework, and pass inspections faster.
Introduction
MachineToolNews.ai received this information directly from Sonibel Instruments. Their latest launch signals a major shift in how weld quality will be managed across structural fabrication, shipbuilding, pipeline work, offshore projects, and defense applications. The company’s torch-mounted acoustic sensor brings real time insight into weld quality, powered by AI that listens to the sound of a weld and detects defects on the spot.
A New Approach to In-Process Weld Quality
Sonibel’s new system mounts directly onto a welding torch and analyzes the high fidelity sound signature of each weld bead. Instead of waiting for post-weld inspection to discover problems, the device identifies issues during the weld itself.
As soon as a defect is detected, the system displays the issue instantly on a screen attached to the welding unit. This supports immediate correction, limits wasted effort, and helps welders pass inspection the first time.
Sonibel states that noisy fabrication environments were a major design challenge. Their approach uses machine learning models trained to separate meaningful weld signals from heavy background noise, ensuring reliable detection even in busy workshops.
Designed for High-Inspection Workflows
In applications where inspection standards are strict, delays can accumulate fast. Every failed weld triggers more downtime, extra weld passes, and repeated nondestructive tests.
Hooman Pirouz, Chief Product Officer at Sonibel Instruments, said:
“We built Sonibel to serve the realities of critical weld operations. In high inspection workflows, the cost isn’t only a failed weld. It is the compounding impact of rework, delays, and repeated inspection cycles. FCAW welds are where we see some of the highest rework costs and where real time visibility can drive immediate return on investment.”
AI That Identifies Defects as They Form
The technology is being optimized to detect porosity and lack of fusion in semi automatic FCAW and GMAW welds. According to Sonibel, custom integration is also possible across other weld processes including GTAW, SAW, SMAW, and laser welding.
The system helps welders correct problems before they propagate through the joint, reducing scrap and cutting down the back and forth between welding teams and inspectors.
Supporting Welders During a Labor Shortage
With pressure rising across fabrication shops, manufacturers are pushing for tools that help welders work faster while maintaining quality. Real time weld defect detection supports both goals. It makes each hour of welding more productive and reduces the uncertainty that comes with manual inspection cycles.
More details on the system are available at sonibelinstruments.com.
About Sonibel Instruments
Sonibel Instruments is a manufacturing quality control company building practical, AI powered tools for welders. Their real time weld defect detection device helps fabricators catch and correct defects earlier, reduce rework, decrease costly delays, and keep projects moving forward.
