Optimizing Surfaces Across Industries
Many of the most stubborn and costly production problems — yield loss, scrap, and downtime — trace back to inconsistent surface quality on parts or tooling. Yet most manufacturers still evaluate surfaces using visual inspection and outdated roughness metrics.
Reduced scrap
Improved yield
Increased production
Surface Design Solutions changes that.
Our Surface Designer platform uses physics-informed AI, trained on the customer’s own data, to identify the surface features that actually control performance. Those insights translate into actionable specifications that integrate directly into existing inspection workflows.
Surface optimization needs a new approach
Manufacturers have more inspection tools than ever before. But most still lack a way to translate surface measurements into actionable insights.
Most manufacturers rely on visual inspection, trial-and-error experimentation, or inspection software that reports generic roughness metrics. Likewise computer vision is useful for detecting scratches or obvious defects, but is insufficient for surface finish overall. By contrast, Surface Designer identifies the surface features that impact performance, without requiring any new equipment or additional QA staff.
Surface optimization in action
Medical devices: single-use syringes
Disposable medical components must perform reliably at scale. Yet even small variations in mold surface finish can cause major swings in production yield, device failures, and costly recalls. With Surface Designer manufacturers can identify the surface features that control performance and help ensure molds produce parts that consistently meet functional requirements.
The Old Way
Unexpected QA failures.
- Receive components from suppliers
- Assemble the devices
- Discover failures in final QA
Result: Higher scrap, inconsistent quality, and expensive troubleshooting.
The Surface Designer Approach
Consistent products through surface intelligence.
- Work with supplier to improve surfaces
- Assemble the devices with confidence
- Consistently pass final QA
Result: Lower scrap, higher yield, and stable production. performance.
Automotive & heavy industry: parts & tooling for powder manufacturing
In powder-metal manufacturing, tooling surfaces play a critical role in product quality. Subtle variations in die polishing can cause powder pull-out, leading to defects, downtime, and the need to repolish tools repeatedly. Surface Designer identifies surface features that control powder flow and tooling performance, enabling manufacturers to polish tools with precision rather than guesswork.
The Old Way
Polishing based on best practices and experience.
- Polish molds using traditional techniques
- Run the press and discover defects
- Repolish molds and repeat the cycle
Result: Inconsistent tooling performance, scrap, and lost production time.
The Surface Designer Approach
Polishing guided by performance-driven surface metrics.
- Polish molds with surface intelligence
- Adjust the process with real-time feedback
- Run production with fewer defects
Result: Higher yields, less downtime, and more reliable tooling performance.
Consumer electronics: the feel of a touch screen
A person’s tactile experience with a product often defines its perceived quality. From touch screens to device housings, the feel of a surface must be carefully engineered. Yet most manufacturers still rely on subjective testing or roughness metrics that fail to predict how a surface will actually feel. Surface Designer connects surface topography directly to human perception, allowing manufacturers to control “feel” with measurable specifications.
The Old Way
Modify the “feel” of products through trial and error.
- Manufacture parts using generic roughness metrics
- Evaluate feel with manual testing
- Experience inconsistent outcomes
Result: Unpredictable tactile quality and inconsistent user experience.
The Surface Designer Approach
Engineer the “feel” of products through measurable surface metrics
- Measure surface topography inline
- Apply advanced, performance-driven metrics
- Ensure consistent tactile quality
Result: Products that feel right, every time.
Expert-led surface analysis & support
While our self-service software platform empowers manufacturers to optimize surfaces on their own, Surface Design Solutions also offers expert guidance to help manufacturers understand, design, and control the surfaces that drive performance. Our customer support offerings are modular and flexible, whether you need hands-on scientific expertise, software tools, or both.