X-Ray & CT Scanning Archives - Industrial Inspection & Consulting

Evaluating Pharmaceutical Medications and Pills using Industrial CT Scanning

INDUSTRIAL CT SCANNING FOR PHARMACEUTICAL EVALUATION

Industrial CT Scanning is used in the pharmaceutical industry to evaluate pills, tablets, and packaging to quantify characteristics like ingredient homogeneity, coating thickness, and drug release.

This case study highlights three common OTC medications to demonstrate how CT scanning can benefit pharmaceutical manufacturers.

Tylenol Rapid Release - RELEASE MECHANISM

CT scanning helps to detect defects such as air pockets, cracks, or uneven coating. These defects could affect the pill’s effectiveness, so identifying them during production is critical. The below image shows a crack within the outer coating and shell.

The Rapid Release shell is a deliberately porous structure designed to increase solubility and the speed of release of the drug.

ADVIL LIQUI-GEL - SHELL THICKNESS

Advil Liqui-Gels contain a liquid form of ibuprofen, and the shell needs to be thick enough to maintain the integrity of the capsule. The shell serves as a barrier that keeps the liquid stable and prevents it from leaking or evaporating before the capsule is ingested. Additionally, the shell thickness helps regulate the rate of dissolution, which is crucial for ensuring the drug is released in a predictable manner.

ALLEGRA 180mg - HOMOGENEITY

Homogeneity refers to the uniform distribution of the active pharmaceutical ingredient (API) and excipients (inactive ingredients) throughout the encapsulated formulation. CT scanning helps evaluate products to ensure that each dose of medication contains a consistent amount of medication, meets granulation and compaction requirements.

CT Scanning Vintage Tobacco Packs for Cards

X-RAY & CT SCANNING VINTAGE TOBACCO PACKS

History like these tobacco packs should be preserved – unless it contains even more favorable collectibles like Honus Wagner, Ty Cobb, or Cy Young cards. As shown in the following image, collectors have been trying for over 20 years to see inside sealed collectibles. This x-ray shows a failed attempt to determine if the pack contains a single card.

This case study demonstrates our ability to locate cards within sealed vintage tobacco packs – with greater confidence using 3D CT Scanning rather than 2D X-ray.

IIC Featured in New York Times for Industrial CT Scanning Services

On December 12th, 2024 Industrial Inspection & Consulting was featured in the New York Times for their excellence in Non-Destructive Testing with an emphasis on X-Ray & CT Scanning. Five months prior, IIC not only turned myth into reality, but scaled this new reality into a viable, cost-effective, world-first service for thousands of potential clients by offering industrial CT scanning for the purpose of identification of sealed collectibles.

Despite the controversy surrounding the service, IIC has partnered with auction and authentication companies to help authenticate high value goods, and manufacturers to help design and test mitigation technologies, and have even developed their own patent for mitigation technologies.

To read the article visit the link below:

X-ray Inspection of PCB Solder Joint Porosity

DIGITAL X-RAY INSPECTION OF PCBs

X-ray inspection is used to inspect the quality and reliability of products containing electronics by revealing hidden defects such as soldering issues, voids, misalignments, and component damage that may not be visible externally. By identifying potential problems early in the production process, X-ray inspection helps prevent failures, reduce rework costs, and enhance the overall performance and longevity of these products. This post demonstrates three inspection tools made possible using high resolution digital x-ray imaging..

1. Solder Pad Fill

X-ray is used to ensure that the solder completely fills the pad to create a strong, conductive joint.

2. fpga wire sweep analysis

X-ray is used to examine the deformation of bonding wires within a microchip package which could potentially cause electrical shorts

3. SOLDER JOINT POROSITY X-RAY INSPECTION

X-ray is used to detect small air pockets or voids within the solder joints of a printed circuit board. We follow custom quality standards provided by our clients to identify areas where process adjustments might be needed. For example, automotive porosity standards typically call for less than 20% porosity in any joint.

Film Radiography vs Digital Radiography

Radiographic Testing can be summarized as interpreting the differential absorption of X-rays. But X-rays are a band of electromagnetic radiation that cannot be detected with human senses (sight, smell, taste, etc.) so, how do we interpret them?

Traditionally this has been done using photographic film. The film has an emulsion layer made up of silver halide crystals. These tiny crystals are light sensitive and X-rays really are just a form of light so, the crystals get excited when exposed to an X-ray.

The X-rays get attenuated at varying rates based on material thicknesses and density. Less X-rays will reach the film (or crystals) when imaging a thick section of an object compared to a thin section. Similarly, less X-rays will reach the film when imaging a more dense part made of steel vs a less dense part made of aluminum. This differential absorption (difference in X-rays making their way to a silver halide crystal) creates a latent image on the film which can then be developed into a permanent photograph with chemical processing that separates the exposed crystals from the unexposed.

Film has been the standard medium for capturing radiographic images since it was first pioneered by Wilhelm Röntgen in 1895. In fact, it still has prolific use in the non-destructive testing industry today. However, these days there are other options which are becoming increasingly adopted.

Digital detector array (DDA) technology was introduced in the last few decades and is becoming increasingly popular as the technology gets better and becomes more affordable. Rather than silver halide crystals, these detectors use a matrix of photodiodes to measure the rate of X-ray absorption. And unlike film, there is no physical radiograph. Instead the image is viewed digitally on a computer.

Film Density & Digital Image Gray Scale

With film the optical density of the radiograph cannot be adjusted after the film has been developed. An optimal density range is targeted using specific exposure settings, film type, and developing time but there is a lot that can go wrong. If the area of interest on the developed film is too dark (or too light) the exposure must be reshot. It takes time and expensive materials to expose and develop a film radiograph. This all goes to waste if a reshoot is required.

With digital imaging you get to see the results right away on your computer screen without a lengthy development time and smelly chemicals. Additionally, the brightness and contrast can be electronically adjusted which provides cushion for less than optimal exposure parameters. To put this into context, the human eye can distinguish about 500 shades of gray, but a digital radiograph taken with a 16 bit detector has 65,536 shades of gray. The 16 bit image has so much information that we cannot actually discern it all by just viewing the raw image alone. To make full use of these thousands of indistinguishable shades of gray we adjust ‘window/level’ (similar to brightness/contrast) to optimize the viewing window for a given area of interest.

Portability

One of the clear shortfalls of Digital Radiography is the need for a power source. This is not an issue in a lab environment but out in the field this means lugging around extension cables and computers. There are some battery operated DDAs out there but this does not fully remedy the power issue if operating for long periods of time or environments with extreme temperatures.

DDAs are also typically rigid and heavy. This makes them tough to set in place. If dropped the DDA could be damaged. Some manufacturers have begun to develop flexible DDAs to address this issue.

On the other hand Film Radiography is extremely pliable. It can be wrapped around a pipe. It can be cut down to size to fit into tight or oddly shaped areas. If combined with a gamma source of radiation, Film Radiography can be performed with no electrical hookups whatsoever.

Another good option for portability is Computed Radiography (CR) with photostimulable phosphor imaging plates. I can’t compare Film & DDA in the field without mentioning CR but that’s a different box of worms for another post. Just know CR can be thought of as a hybridization of Film Radiography and DDA Digital Radiography. They all have their use cases.

Automation & AI

With Film Radiography every piece of film is single use. Once the silver halide crystals are exposed they cannot be reverted back to their original state. The film must either be developed or discarded. This make Film Radiography inherently impractical for automating inspections.

Some time can be saved by using custom built fixtures or an automatic processor for the development process, but in general the image acquisition is a very manual and time consuming process.

Also, because Film Radiography is an analog process with a physical media for storing data; analysis of data cannot be aided with today’s AI computer vision models.

In contrast with Digital Radiography, a DDA is reusable and can be integrated with PLCs to develop image acquisition programs which are fully automated and repeatable. This greatly saves time and cost of consumable materials when compared to Film Radiography.

These images can also be sent directly to computer vision models for analysis with AI. This is a capability that some NDT manufacturers are investing heavily into at the moment.

CT Scanning PCB Microchips

Micro-CT (micro-computed tomography) scanning has become an essential tool for inspecting microchips and PCBs (Printed Circuit Boards) in the electronics industry. The technology allows for non-destructive, high-resolution internal imaging, which is crucial for ensuring the quality and performance of microchips and PCBs.

Below are some CT scan images of a microchip and some beneficial reasons for CT scanning these critical components.

Preservation of Samples: Micro-CT scanning allows for the inspection of microchips and PCBs without physically damaging them. This is especially critical for high-value components or prototypes where any damage could lead to costly delays or failures.
Internal Inspection: Unlike traditional techniques, such as X-ray inspection, micro-CT allows for the detailed visualization of the internal structures of microchips, such as the bonding wires, die, and underfill, without disassembling the components.
Inspection of Assembly Integrity: In addition to inspecting individual microchips, micro-CT scanning is highly effective in checking the quality of the entire PCB assembly, including:
- Placement accuracy of components (such as resistors, capacitors, and chips)
- Via integrity (e.g., detecting voids or solder bridges in vias)
- Trace continuity and checking for potential issues in signal paths or power distribution
Micro-Solder Joint Inspection: Micro-CT is particularly valuable for examining solder joints, which are often located in hard-to-reach areas. It can check for the presence of solder voids, underfill problems, or even assess the amount of flux residue left over.

Failure Analysis: Micro-CT scanning can identify faults within microchips and PCBs that are invisible to the naked eye or traditional inspection methods, such as:
- Solder joint failures (e.g., cracks, cold solder joints, or voids)
- Delamination in multi-layer PCBs
- Corrosion or oxidation within microchips
Process Optimization:
- Feedback for Manufacturing Process: Data obtained from micro-CT scans can be used to fine-tune manufacturing processes. For example, if a high defect rate is found in a specific area of the PCB, the manufacturing process can be adjusted to address that issue and improve yield.
- Supply Chain and Component Analysis: Micro-CT scanning can also be used to inspect incoming components from suppliers, verifying that they meet the required specifications and quality standards before they are incorporated into the final product.

Using X-Ray & CT Scanning to Identify Mystery Box Collectibles

In 2005, Hasbro launched a Star Wars collectible action figure game called Attacktix, which became a childhood obsession of mine. The game featured hundreds of characters to collect, each sold in mystery boxes containing three figures. Part of the excitement came from not knowing who you’d get until you opened the box at home, always hoping for a rare figure like Boba Fett.

Nowadays, there are all kinds of different mystery box toys on the market. I purchased 5 unique brands to see if we could use the power of attenuating radiation to see what is inside without opening them.

Starting off is Jurrasic World Captivz Hatchling Dinos.

CT scanning showed some paper, sand, & a plastic figurine. After isolating the figurine, and matching the features of the jaw & the tail it became clear that it was the brown/tan baby t-rex.

Next up is the Dragon Battle Figure Series. This one has 5 different possible figures. Using CT scanning we isolated the figure inside the pouch. Based on his pose it is clear that this one is the legendary Super Saiyan himself, Broly!

Now on to the Stumble Guys. This cool green hat packaging comes with 2 unique figurines inside. Rather than isolating the 3D models, I relied on the 2D views for this one. I was able to find a figure that looked like a lion and one that looked like a box of cereal. This can only be ‘Leonidas’ & ‘Killer Size’.

Onto Roblox. Here we CT scanned a mystery figure from Series 12. I was confused when I first opened up the file. I just saw a big oval, after doing a little digging it was clear it could only be ‘Lemon Head’. He got that skibidi toilet rizz.

Lastly is a Series 5 set from Star Wars Micro Galaxy Squadron. At this point I decided to challenge myself and see if I could detect what was inside with just a single, quick 10 second x-ray image. I had a hard time telling by the figurine alone, but the features of the speeder made it obvious that this is the blue mandalorian.

X-Ray & CT Imaging of Endoscopy Medical Device

X-Ray CT Inspection of Pillcam

Pill cameras, or “pillcams,” are small, ingestible devices used to capture images of the inside of the gastrointestinal tract. They are particularly useful for diagnosing conditions like Crohn’s disease, ulcers, and cancers in areas that are hard to reach with traditional endoscopy, such as the small intestine. The main benefit of pillcams is that they offer a minimally invasive, comfortable alternative to more traditional procedures, allowing doctors to observe the GI tract in real time as the pill moves through the system.

Industrial CT scans can assess the alignment and assembly of small, complex parts inside medical devices like pillcams, ensuring that all components are correctly positioned and functioning as intended. This technology offers high-resolution 3D imaging, allowing for precise analysis of intricate details that would be difficult to detect with traditional inspection methods like X-ray or visual inspection. Thus, CT scanning plays a critical role in ensuring that medical devices meet safety, performance, and quality standards before being released for use.

Battery evaluation for alignments, connections, and spring contact
Micro-PCB showing solder joint porosity

Diagnosing Failure Within a CubeSat Using Industrial X-Ray & CT Scanning

DIAGNOSING FAILURE WITHIN A CUBESAT

Industrial Inspection played a critical role in diagnosing a failure within this CubeSat. Set to launch on a SpaceX rideshare in November 2024, our client walked into our lab with a defective, seven-figure satellite and walked out with a plan for repair. We were challenged to determine the defect within one day so that build technicians would have enough time to tear down and repair or replace necessary components. Armed with only suggestions of possible zones for failure, our certified experts took on the challenge of finding this needle in a haystack.

“Our staff is comprised of world class inspection experts hailing from renowned inspection labs, space companies, and defense contractors. We thrive under pressure and perform at our best when failure is not an option,” said Keith Irwin, Managing Partner of Industrial Inspection.

THE CHALLENGE

Large, complex systems like this CubeSat present a variety of challenges for Industrial X-Ray Imaging & CT Scanning. For example, opposing parameters like resolution versus energy must be weighed for their pros and cons. Without enough energy there would be a lack of penetration and increased x-ray artifacts. But, higher energy also introduces a larger x-ray spot-size and reduced resolution.

When imaging PCBs and searching for cracks or foreign object debris, resolution reigns supreme. Because of this, we swapped our 320kv mesofocus x-ray source (>30um resolution) out for our 225kv microfocus source (>3um resolution) in our large format x-ray cabinet. In order to locate any potential defects we must work through increased noise and artifacts to find miniscule defects.

Below is the point of failure – the signal amplifier likely overheated causing fracture. The left image shows a cross-sectional view through the side of the component, the middle view shows a top-down cross-section, and the right view shows the 3D render with the location of the component.

REACTION WHEEL IMAGING

Other areas of the satellite were also imaged for general information purpose like this reaction wheel and its copper windings.

Powered by batteries energized by small solar panels, reaction wheels are the preferred method for attitude control and stabilization. When a wheel spins, it creates angular momentum in one direction, causing the spacecraft to rotate in the opposite direction. By changing the speed of the wheels, the satellite can control its orientation in space without using propellant. This is particularly useful for precise pointing of instrumentation without the need for propellant.

All information has been shared with permission by our client.

CT Scanning Tensile Strips

Tensile strips are manufactured materials used to measure or apply tensile stress in various applications. They are often used in structural engineering and material testing to evaluate the strength and elasticity of materials under tension. They come in a variety of shapes, sizes, and materials.

However, the sample in this case study is for a different purpose. While some manufacturers look to eliminate as much porosity as possible, others attempt to create a distribution of porosity for reasons like: flexibility, sound absorption, thermal insulation, and product lightening.

Industrial CT Scanning is used to characterize, quantify, and create 3D representations of these strips for failure analysis and FEA. Data can be exported into a variety of file formats.

Category: X-Ray & CT Scanning