At MIRTEC, we are committed to supporting global manufacturers in strengthening quality control and advancing production standards. We are proud to support ZF Group, a global leader in automotive technology, in enhancing its conformal coating inspection process with MIRTEC’s GENESYS-CC system.
ZF Group is a global technology company supplying advanced mobility systems for passenger cars, commercial vehicles, and industrial applications. With a strong focus on safety, reliability, and long-term performance, ZF operates highly complex electronics manufacturing environments where consistent quality assurance is critical.
As electronic assemblies in automotive applications continue to increase in density and functional complexity, conformal coating has become an essential process to protect PCB reliability under harsh operating conditions. Ensuring the quality and consistency of conformal coating coverage is therefore a key requirement in ZF’s manufacturing strategy.
Automotive Quality Requirements
In automotive electronics production, conformal coating defects such as insufficient coverage, bubbles, excess coating, or contamination can lead to serious reliability risks. Traditional inspection methods and manual checks are often limited in repeatability and struggle to provide consistent results at scale.
ZF Group required an inspection solution capable of accurately verifying conformal coating quality across complex PCB assemblies, while maintaining high throughput and supporting automated production environments. The system needed to reliably detect coating-related defects without slowing down production or increasing operator dependency.
To meet stringent automotive quality standards, ZF sought an advanced inspection solution that could deliver objective, repeatable results while providing clear visualization and data to support process control and continuous improvement.
GENESYS-CC Implementation
After evaluating available technologies, ZF Group selected MIRTEC’s GENESYS-CC, a dedicated conformal coating inspection system designed to address the unique challenges of coating inspection in modern electronics manufacturing.
While there are many companies well recognized for their conformal coating inspection technologies and market presence, ZF Group ultimately selected MIRTEC’s GENESYS-CC as the best fit for its conformal coating inspection requirements.
The decision was driven by confidence in MIRTEC’s inspection expertise and the GENESYS-CC system’s ability to deliver accurate, stable, and automated inspection results in high-reliability production environments.
Dedicated Conformal Coating Inspection Capability
The GENESYS-CC is specifically engineered for conformal coating inspection, utilizing advanced imaging and illumination techniques to clearly identify coating presence, uniformity, thickness-related issues, and coating defects across complex PCB geometries. The system enables reliable detection of common coating faults that are difficult to identify through manual inspection alone.
The GENESYS-CC stands out from competing conformal coating inspection systems with three distinctive optical features.
First, GENESYS-CC provides an option to overcome the challenges of bubble detection. By selecting the high-resolution 4µm lens, it is possible to detect bubbles as small as 60µm with exceptional precision. This advanced optional optical system ensures flawless bubble detection with unparalleled inspection accuracy.
Second, the system features a 3-stage UV lighting configuration. The system incorporates three UV-enabled lighting stages, enabling compatibility with a wide variety of coating materials such as acrylic and silicone.
The last distinctive feature is the side camera for lateral coating inspection. The inclusion of a side camera allows for thorough inspection of side-coated areas, enhancing the overall inspection capabilities.
In addition to these standout features, MIRTEC’s GENESYS-CC is capable of measuring coating thickness of most acrylic and silicon coating materials. Also, the optional flipper conveyor applied inside the machine allows double-sided PCB inspection without the need for an external flipper.
This dedicated approach enables ZF Group to maintain consistent coating quality while significantly reducing the risk of escapes that could impact downstream reliability.
Automation and Production Integration
Designed for inline operation, the GENESYS-CC integrates seamlessly into automated production lines. The system supports stable, repeatable inspection at production speeds, minimizing operator intervention while ensuring inspection consistency across shifts and product variants.
Usability and Process Confidence
The GENESYS-CC offers an intuitive user interface and efficient programming workflow, allowing operators and engineers to quickly establish inspection programs and maintain confidence in inspection results. Clear visualization and inspection feedback support rapid decision-making and effective process control on the production floor.
The system’s flexibility also ensures ZF Group can adapt to evolving product designs and future coating requirements without compromising inspection capability.
Supporting Long-Term Manufacturing Excellence
With the implementation of MIRTEC’s GENESYS-CC, ZF Group has strengthened its conformal coating inspection process, improving inspection consistency and reinforcing quality assurance for automotive electronics production.
By adopting a dedicated, automated inspection solution, ZF Group enhances product reliability while supporting efficient, scalable manufacturing operations. MIRTEC is proud to support ZF Group in maintaining the highest standards of quality and performance and looks forward to continuing this partnership as manufacturing requirements for the Automotive Industry continue to evolve.
To learn more, visit www.mirtec.com.
