How are you ensuring the surface integrity of your components? In manufacturing industries like automotive, aerospace, fasteners, agriculture, and medical, even the smallest surface discontinuities, such as cracks, nicks, and laps, can create serious risks. A single missed defect can lead to part failure, safety issues, warranty costs, and unhappy customers.
Many manufacturers still rely on manual inspection methods such as Magnetic Particle Inspection (MPI), Fluorescent Penetrant Inspection (FPI), and Dye Penetrant Inspection (DPI). These processes have been used for years, but their limitations are becoming harder to ignore.
There is a better option. Eddy current inspection with FOERSTER’s STATOGRAPH product family offers a cleaner, faster, and more reliable way to verify surface quality.
Traditional inspection methods no longer meet the reliability that modern production needs. Premature failures, customer returns, safety concerns, quarantined batches, and warranty claims can all be traced back to inconsistent surface inspection. As production volumes grow and tolerances tighten, manual testing introduces too much risk.
Automated eddy current testing removes this uncertainty. When used in your quality process, systems like the STATOGRAPH provide clear advantages.
Even a 1% scrap or rework rate can damage your margins. Manual testing may even reject good parts or allow bad parts to pass.
The FOERSTER STATOGRAPH product family helps prevent these issues. Utilizing proven eddy current technology, the STATOGRAPH systems detect surface discontinuities with a high level of precision and repeatability.
The FOERSTER STATOGRAPH product portfolio includes multiple hardware and software tools designed to solve specific pain points in modern manufacturing. Below is a breakdown of how each system helps eliminate the shortcomings of MPI, FPI, and DPI while giving you superior detection confidence.
These systems are ready for modern manufacturing and support easy integration into connected production lines. Users can access the equipment from mobile devices, adjust parameters through an automated setup wizard, and connect through fieldbus or Profinet networks. A wide range of standard, flexible, and custom probes make it easier to test both simple and complex geometries.
Key advantages of the STATOGRAPH CM+ / CM include:
The STATOGRAPH TCL is easy to integrate and simple to operate. It supports automatic probe recognition, which loads the correct settings through a data chip, reducing operator error. . Touch-friendly software, setup wizards, multiple signal charts, and built-in report generation make the system intuitive for operators and reduce training requirements.
Key advantages of the STATOGRAPH TCL include:
The STATOVISION uses intelligent pattern recognition filters that remove interference from drill holes, grooves, chamfers, and other features. This allows true defects to stand out, even in areas that were once considered untestable. Users can also store raw data, compare scans, and identify trends such as tool wear. The software supports post-processing and generates reports in PDF, PNG, or CSV formats. This makes the STATOVISION a valuable tool for both inspection and long-term process improvement.
Key advantages of the STATOVISION include:
To ensure each solution meets the customer’s exact needs, FOERSTER offers full application studies in our Salem, Ohio, lab. Customers send in their actual components, and our team performs detailed testing to evaluate surface conditions, simulate real production scenarios, and confirm detection performance. These studies allow us to compare STATOGRAPH results with existing methods such as MPI, FPI, and DPI. In many cases, our systems detect flaws that manual tests miss.
Once testing is complete, we provide a detailed report, video documentation, and a recommended system configuration that improves speed, cleanliness, repeatability, and long-term cost efficiency. This gives manufacturers complete confidence that a FOERSTER solution will meet their quality and production goals.
An added advantage is that the Salem facility is also where we design and build our custom turnkey automated systems. This means everything happens in one place. Ideation, feasibility studies, system design, manufacturing, installation, and operator training are all done by the same team, using the customer’s actual parts. The result is a fully tailored solution that fits seamlessly into the customer’s production process from day one.
Many manufacturers continue to rely on Magnetic Particle Inspection (MPI), Fluorescent Penetrant Inspection (FPI), and Dye Penetrant Inspection (DPI). These methods are slow, messy, subjective, and expensive to maintain. The STATOGRAPH product family offers a faster, cleaner, and more reliable way to inspect surfaces and prevent escapes.
By choosing a system from the STATOGRAPH product family, you gain clear advantages, like:
FOERSTER can prove this through an application study. We test your real components, confirm detection capability, and often reveal defects that MPI, FPI, and DPI do not catch. After the study, we recommend a solution that improves speed, cleanliness, repeatability, and cost efficiency.
If you are ready to move beyond manual testing, the STATOGRAPH product family can help you build a more reliable inspection process. Your components and your customers deserve the highest level of confidence.