Work on the Integrity Inspection tools progressed with the first version of the Mechanical Hardness Inspector (MHI) app and initial lab tests on the induction hardening bench. Samples treated under varying heating and cooling conditions were analyzed for hardness and microstructure. The supercontinuum laser was completed, and the Phased Array ultrasonic inspection solution advanced with 12 weld samples tested.
For the Visual Inspection tools, the main focus was consolidating requirements and defining architectures, mock-ups, and datasets for each application. A set of support services was also defined, including feasibility analysis, hardware setup, and model training.
In the Thermal Inspection tools, work established the Thermal Inspection Suite through defining requirements, architecture, mock-ups, and dataset features. Functional and Pilot Requirement Diagrams were prepared, and a common roadmap with other technical WPs ensured alignment in designing the suite’s applications.
Additionally, the preparatory works for interoperability and integration of the developed solutions has been carried out. In general, a big part of the activity in this period, has been related to define the initial set of documents for the software: mockups, requirements, software specification, top ten features, etc. A significant amount of time has also been dedicated to prepare plenaries and meetings, presentations, demos and the deliverables including the on-line documentation.
To conclude, piloting and demonstration works also started. Work is divided in 4 phases. Phase 1 'Pilot Implementation definition, planning and KPI validation Criteria' made the detailed definition of the Pilot and plan its development and implementation. In addition, this phase also collected the users’ requirements and validation criteria to be assessed in terms of univocally determined real values of defined KPIs. In phase 2 'Pilot industrial scenario establishment', a clear overview of the industrial sector of the pilot’s cases was translated into common constraints and criteria. Environmental barriers and possible obstacles were identified to be tackled during the development phases. These first two phases are already completed.
During the second reporting period, ZDZW (Zero Defect Zero Waste Manufacturing) reached full technological maturity, validating and demonstrating its suite of Non-Destructive Inspection (NDI) solutions across six industrial pilots in five strategic sectors — automotive, home appliances, renewable energy, e-health, and food & beverages. The project successfully developed, integrated, and validated 18 digital inspection applications, grouped into three technological suites: Integrity, Visual, and Thermal Inspection, all interoperable through a common ZDZW digital platform that provides traceability, data management, and “Inspection-as-a-Service” functionalities.
Main Scientific and Technical Achievements
- Development of three complete inspection suites (Integrity, Visual, Thermal) integrating AI, Digital Twins, and advanced sensing.
- Creation of a fully interoperable digital platform connecting all solutions under a unified Inspection-as-a-Service ecosystem.
- Demonstrated defect reduction, energy and material savings, and increased process reliability across six pilots.
- Established European leadership in ZDM/ZWM, contributing to the CEN Workshop Agreement 18230:2025 and multiple scientific publications.
- Validated industrial scalability and exploitation readiness through the Beta Testing Campaign and Viability Plan.
In conclusion, ZDZW has achieved its scientific and technical objectives, delivering a validated and market-ready ecosystem of interoperable NDI tools and digital services that enable European industries to transition toward zero-defect, zero-waste, and fully sustainable manufacturing.
