ZEISS BOSELLO Series Industrial Micro-CT System

Overview

The ZEISS BOSELLO Series Industrial Micro-CT System is a high-performance, production-grade X-ray inspection platform engineered for non-destructive evaluation (NDE) of castings, additively manufactured components, and precision-engineered parts in demanding manufacturing environments. Unlike conventional 2D radiography systems, the BOSELLO platform integrates optional computed tomography (CT) capability—enabling true volumetric reconstruction with sub-micron spatial resolution and nanometer-level dimensional accuracy when configured with high-magnification optics and precision motion control. The system operates on the principle of cone-beam X-ray CT: a microfocus or nanofocus X-ray source projects radiation through the sample onto a high-dynamic-range CMOS detector; multiple projections acquired during controlled TR (translation-rotation) scanning are reconstructed into 3D voxel datasets using filtered back-projection or iterative algorithms. This architecture supports both rapid 2D real-time radiography for inline process monitoring and high-fidelity 3D CT for metrology-grade internal defect characterization—including porosity distribution, inclusion morphology, crack propagation paths, and wall thickness variation—fully traceable to ISO/IEC 17025-accredited measurement protocols.

Key Features

• Modular TR (Translation-Rotation) scanning architecture optimized for geometric stability and mechanical repeatability under thermal and vibration loads typical of factory-floor deployment.
• High-resolution CMOS semiconductor detector with >16-bit dynamic range, low noise floor (<1.5 e⁻ RMS), and pixel pitch down to 50 µm—enabling detection of sub-10 µm features in dense metallic samples.
• Integrated microfocus X-ray source (optional nanofocus upgrade) delivering stable tube voltage (40–225 kV) and current (0.1–1.0 mA), compliant with IEC 60601-2-44 and EN 62464-1 safety standards.
• Ruggedized industrial cabinet design rated IP54, supporting continuous operation at ambient temperatures from 15–30 °C and relative humidity up to 70% non-condensing.
• Native support for ASTM E1441 (Standard Guide for Computed Tomography), ASTM E2698 (Standard Practice for Radiographic Examination Using Digital Detector Arrays), and ISO 15737 (Industrial Computed Tomography).
• Factory-integrated motion control with encoder feedback and thermal drift compensation—ensuring long-term geometric calibration stability per VDI/VDE 2630 Part 1.2.

Sample Compatibility & Compliance

The BOSELLO Series accommodates part sizes ranging from Ø10 mm × 10 mm (small electronics assemblies) to Ø600 mm × 800 mm (large automotive castings), with maximum sample weight up to 50 kg. Material compatibility spans aluminum, magnesium, titanium, steel, ceramics, and polymer composites. All configurations comply with EU Machinery Directive 2006/42/EC, Electromagnetic Compatibility Directive 2014/30/EU, and RoHS 2011/65/EU. For regulated industries—including aerospace (AS9100), medical device manufacturing (ISO 13485), and automotive (IATF 16949)—the system supports audit-ready documentation packages, including IQ/OQ/PQ protocols, uncertainty budgets per GUM (JCGM 100:2008), and full traceability to NIST-traceable reference standards.

Software & Data Management

Acquisition and reconstruction are managed via ZEISS INSPECT CT software—a validated, 21 CFR Part 11-compliant platform featuring role-based user access, electronic signatures, and immutable audit trails for all acquisition parameters, reconstruction settings, and measurement reports. The software includes automated defect recognition (ADR) modules trained on metallurgical defect libraries per ASTM E2862 (Standard Guide for Digital Radiographic System Evaluation), with configurable sensitivity thresholds and false-positive suppression logic. Export formats include DICOM-CT, VGStudio MAX-compatible .vol, STL, and CSV-based metrology reports. Raw projection data is stored in HDF5 format with embedded metadata (exposure time, source-detector distance, rotation angle), ensuring full reproducibility and third-party interoperability.

Applications

• Porosity quantification and 3D pore network analysis in high-pressure die-cast aluminum engine blocks (ASTM E1558)
• Dimensional validation of internal cooling channels in investment-cast turbine blades
• Crack depth and branching assessment in post-weld heat-treated weld joints
• Void mapping and binder burnout residue detection in metal injection molded (MIM) components
• First-article inspection and PPAP submission support for Tier-1 automotive suppliers
• Root cause analysis of fatigue failures via 3D defect co-location with stress simulation outputs (e.g., ANSYS Mechanical)

FAQ

Does the BOSELLO Series support full-volume CT reconstruction with metrological traceability?
Yes—when equipped with ZEISS METROTOM calibration artifacts and operated under temperature-stabilized conditions, the system achieves volumetric measurement uncertainty ≤ (2.5 + L/100) µm (k = 2) per VDI/VDE 2630 Part 1.3.
Can ADR rules be customized for proprietary defect classes?
Yes—INSPECT CT allows rule-based scripting using Python APIs, enabling integration of customer-specific metallurgical criteria and statistical process control (SPC) limits.
Is remote diagnostics and software update support available globally?
ZEISS offers 24/7 remote service access via secure TLS-encrypted connections, with firmware and software patches distributed through the ZEISS Service Portal—compliant with ISO/IEC 27001 information security management.
What is the typical lead time for CT system installation and qualification?
From order confirmation, standard BOSELLO MAX or HEX configurations require 14–18 weeks for factory acceptance testing (FAT), site preparation coordination, and on-site operational qualification (OQ).
Are third-party CT reconstruction engines supported?
Raw projection data exports are fully compatible with commercial (e.g., Thermo Fisher Avizo, Volume Graphics VGStudio MAX) and open-source (e.g., TomoPy, ASTRA Toolbox) reconstruction frameworks.