How Non-destructive X-ray CT Reveals Internal Failures in Compact, High-performance Devices

When You Need Answers Without Opening the Device

Smart rings, sensors, medical electronics, and smartwatches are fast becoming the popular wearable tech of today. The miniature nature of the components within these devices makes for challenging inspection when failures happen or design changes are needed. The growing complexity of the mini-electronics sealed within the wearables calls for a non-destructive technology like X-ray CT scanning to visualize and diagnose defects. In this article, Nel PreTech takes a 360° scan of a defective Oura Ring to demonstrate the effectiveness of wearable electronics inspection for internal failure analysis.

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Why Traditional Teardown Falls Short for Wearables

High-performance device manufacturers are creating multi-material assemblies with compact internal architecture, micro-electronics, and integrated battery components. These attributes make them a unique product with unique inspection needs. In the past, physical teardown of a device could cause issues: 

• Destruction of evidence
• Loss of dimensional and assembly context
• Inability to re-test or validate root cause

Now, with industrial CT scanning at the forefront of internal assembly inspection, consumer electronics companies are reaping the benefits of fast, accurate, and thorough data for informed decision-making. 

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How Industrial CT Scanning Works for Miniaturized Electronics

Different types of CT scanners work in slightly different ways. Nel PreTech employs CT scanners made by Zeiss Corporation. The machines in our lab have an X-ray source and a detector for image acquisition. There is a rotary table in between the two that holds the sample and spins it 360° to acquire the slice-by-slice internal and external, voxel-based images. Specialized software is used to visualize the volumetric reconstruction and interrogate the data. The high-resolution capabilities of CT scanning make it viable for micro-components without losing important geometries or fine details like solder joints. Industrial CT scanning is also suitable for materials like metal alloys, ceramics, polymers, and more. 

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Case Example: CT Scanning a Defective Oura Ring 

In the video below, you will see the imagery we obtained using a Zeiss Metrotom 1500 CT machine to scan an Oura Ring known to be defective. This scan was performed at 10.09 microns. Anode battery layers, circuitry, and mechanical features can be detected in full volumetric view without cutting open the device.

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Types of issues CT can help identify in devices like this:

• Battery swelling or deformation
• Misalignment of internal components
• Solder joint defects or shorts
• Assembly or dimensional inconsistencies

What CT Reveals That Other Methods Cannot

The diagnostic advantages of using industrial CT scanning on compact wearable devices are profound. Here are some of the capabilities:

• Internal battery condition and placement
• Micro-solder joint integrity
• Wire routing and connectivity
• Hidden voids, cracks, or manufacturing defects

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Visual inspection, electronic testing alone, and destructive cross-sectioning won’t provide the detailed information to conduct a thorough review of defects or anomalies. These methods stand in stark contrast to being able to identify internal battery swelling, misalignment, or shorts, or to evaluate assembly and dimensional integrity.

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Applications Beyond Consumer Wearables

The relevance of industrial CT scanning can be expanded to broader industries, including:

• Medical-grade devices and sensors
• Implantable or skin-contact devices
• Defense and aerospace electronics
• R&D prototypes and failure analysis labs
  
  

CT scanning is a strategic tool across all areas of the product life-cycle. It can be implemented during any of these stages, seamlessly and effectively:

• Product development
• Design validation
• Quality assurance
• Failure analysis and root cause investigations

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CT Scanning in R&D and Quality Assurance Strategies

Experts in research and development and quality assurance can use computed tomography data to inform decision-making for:

• Validating design intent
• Improving assembly processes
• Reducing warranty claims and field failures
• Maintaining traceable records
• Preserving evidence for regulatory or internal reviews

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Why Work With an Experienced Industrial CT Partner

When you choose to work with Nel PreTech labs, you are engaging with trusted experts in the field of 3D and CT scanning for manufactured products. Accredited to ISO/IEC 17025, our people, process, and platforms offer advanced solutions for process and failure analysis. When scanning high-value or delicate electronics, expertise matters. We have a proven track record of working with compact devices and challenging inspection scenarios. For added assurance, we provide reports of measurement uncertainty with a robust and accredited quality management system. Not all scans are created equal. With a deep understanding of CT scanning nuances, our lab produces accurate scans and images built upon X-ray expertise.

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Get Answers Without Destruction

If you’re developing or manufacturing miniaturized electronics, industrial CT scanning is a must-have service. To fully see inside and outside your products, get the data you need without a teardown. We invite you to request a free quote or talk to our CT scanning experts:

nelpretech.com/get-a-quote

708-429-4887

info@nelpretech.com