Shiny surfaces. Parts still moving. Defects nobody can write a rule for. DESSAR is an applications engineering company for exactly those problems — we pick the sensor to suit the part, build the cell around it, and stay until the line runs it unattended.
Feasibility first: send samples or images and we come back with what is detectable, at what rate, and what it takes.
DESSAR Systems India was incorporated in 2023. The figures above are the combined record of the engineering team that founded it, carried over from a decade of machine vision work before that.
One team covers the optics, the lighting, the measurement and the interface to your line, so nothing gets handed off mid-problem.
Presence, position, orientation, print and surface checks at line rate — the workhorse inspections, done properly.
Laser line and snapshot 3D for height, flatness, step, volume, weld and glue beads — including on surfaces too reflective for 2D.
For defects nobody can reduce to a rule: soil, scratch, texture, cosmetic variation. Trained on your parts, tuned on your reject rate.
Outer and inner diameter, PCD, concentricity, length and height — gauged in line, at production speed, on every part.
Bubble leak testing read by camera rather than by eye, with the decision logged against the part.
Camera-based monitoring of robot and welding cells: intrusion, guard state, and the conditions an interlock alone will not catch.
Road, test-track and perimeter monitoring where subjects move fast and lighting cannot be controlled.
Bore, weld and surface examination with measurement and reporting for lab and incoming quality.
Two sectors where we have worked the applications end to end and can show you the measurement, not a brochure. The detail behind each — sensor selection, accuracy figures, installation and programme — is issued against your own application.
Seven measurement points across a railway, from the depot to the wayside to the vehicle itself.
Three applications on one sensing platform, aimed at the joints your customer judges first.
Beyond these: electronics, pharmaceuticals, FMCG, metals and engineering, smart city infrastructure and research laboratories. If your part is difficult, the sector matters less than the surface.
A few of the cells running on customer floors.
Sheet metal fabrication
A ceiling-mounted six-axis cobot carries a 3D laser line profiler over each panel along a multi-pose scan path, measuring features that a fixed camera cannot see from one viewpoint. Conveyor infeed and outfeed, guarded cell with light curtain, and an inspection portal where operators see the verdict and quality sees the history.
Electrical components
A purpose-built machine with twin rotary indexers and vision at several stations, checking pitch circle diameter, concentricity, length and height on every terminal — at a hundred thousand parts a day, with rejects diverted automatically.
Energy equipment
A cobot walks two cameras through twenty-three poses to cover around a hundred and forty regions on an assembled panel — component presence, label reading, wiring checks and dimensional gauging combined in a single pass, replacing an inspection that took an operator several minutes.
Automotive
Camera coverage along 2.2 km of proving ground, detecting vehicles, incidents and track intrusions in real time so control room staff are alerted rather than expected to watch.
Robotics and welding
An AI camera watching a welding cell for unsafe states and approach conditions, tied into the cell's own safety logic.
Grinding burn, chatter, scratches, dents, rust bloom, pitting, raceway damage, a chipped shield. The defects that matter on a bearing are small, they are cosmetic and structural at the same time, and most of them cannot be written down as a rule an operator or a fixed threshold could apply. Miss one and it leaves the plant inside an assembly.
Two things make it hard. The surface is ground steel — bright, curved and specular, so lighting decides whether a defect appears at all. And a defect can sit anywhere: either face, the outer periphery, or down the bore. A part that is only inspected on the side facing the camera has only been half inspected.
So the machine has to present all four surfaces to a camera, under controlled light, without slowing the line. Below are two ways we have engineered that. Run either one and drive it yourself — orbit the view, start the cycle, watch the stations work.
The table is glass, so one camera sits underneath and looks straight through it at the lower face while the top camera and dome light take the upper face. The dome is what makes a scratch on ground steel visible instead of lost in glare. A servo spindle spins the ring at the second station so the whole periphery passes the camera, with an endoscope entering on the bore axis for the raceway. Accepted bearings leave on a belt; only rejects are pushed off.
Drag to orbit, scroll to zoom, and use the controls to step the cycle. Open it full screen
The ring slides between open jaws, gets clamped on its faces and turned 180°, so both faces are imaged by dedicated cameras with their own lighting rather than one camera and a mirror — each face gets the illumination its defects need. Downstream, a lift raises the bore around a fixed borescope while the part spins, covering the periphery and the bore in the same move. Rejects are separated by defect family into their own lanes, so the pattern of what is failing stays visible.
Drag to orbit, scroll to zoom, and use the controls to step the cycle. Open it full screen
Both approaches are shown for discussion. Geometry is schematic and not to scale — dimensions, optics and cycle times follow detailed engineering against your part and your rate. Which defects are detectable, at what size and at what rate, comes out of a feasibility on your own parts: send us good ones and rejected ones, and we will tell you what the images actually support before anyone designs a machine.
We supply and support the components we build with, so one contract covers both the system and what is inside it.
Area and line scan cameras, 3D laser profilers and snapshot 3D sensors, illumination and optics, encoders, measurement machines, smart cameras and edge inspection platforms — specified for the application, not sold from a catalogue.
Working across automotive, electronics, pharmaceuticals, FMCG, metal and engineering, smart city infrastructure, and research laboratories.
DESSAR Business System — One Business Suite. We run our own floor on it every day.
By the time the numbers agree, the month is over. So we built the whole thing into one.
Quote in minutes with tax worked out for you. Add a customer from the GSTIN alone. See who is on the floor, what is below reorder level, which machine has been called out three times this year — and where the order book stands, in five seconds.
Runs on the server in your own plant, or a small cloud plan. Your data stays under your control.
Bring in all forty people. The bill does not move when the team grows.
Built for a team of ten to fifty, not a boardroom. Days to go live, not quarters.
Describe the part and the defect you are chasing. You will get an honest answer on what vision can and cannot do for it, and what it would take to prove it on your line.