In high-volume metal forming processes such as extrusion, rolling, and pressing, precision and repeatability are paramount. Yet, even in tightly controlled environments, material defects can emerge. One particularly elusive and damaging defect in aluminum extrusion is the formation of blisters, also known as pinhole blowouts, localized weak spots caused by trapped gas within the metal.

Traditional quality assurance tools, including optical and infrared sensors, often fall short in detecting these faults in real time—especially in the harsh, noisy, and dusty environments typical of heavy industry. However, these defects often produce a telltale sign: sound.

Noise in an industrial facility is normal. But what happens when parts of a process begin to deteriorate? Often, the sound signature of equipment will change—gradually over time, or suddenly through acoustic events that signal faults or failures.

In industries like shipping, pulp and paper, oil and gas, and metal production, critical systems are typically equipped with a variety of sensors to measure performance and stability, also known as asset management or condition monitoring. Despite this, one of the most vital diagnostic tools remains the operator’s ear, which is trained to recognize subtle shifts in how equipment sounds. Replicating this sensory expertise digitally, especially in noisy, harsh environments, has long been a challenge.

In the world of serial production, especially when dealing with rotating equipment like pumps, fans, and motors, precision and repeatability are everything. Before any unit leaves the factory, it typically undergoes a series of quality checks. One of the most telling – and traditionally subjective – is the acoustic test: does this unit sound like it's supposed to?

Can you hear repeating failure in your production line or process facility? What about the production equipment you use? If you can tell in an instant when something is off in the sound signature, where the sound is a key indicator of faults that might not meet the standards of the finished product, Squarehead can digitalize and automate that human sense and experience – even in extremely noisy environments.

When developing a new product, every detail matters, including how the product sounds. Whether it’s the hum of a motor, the whirr of a fan, or the subtle vibrations of moving parts, noise isn’t just a byproduct – it’s a performance indicator. In fact, unexpected or undesirable sound emissions during R&D can signal hidden issues with design, component compatibility, or mechanical tolerances.

autonomous vessels, the accurate detection, localization, and monitoring of sound sources become critical for effective operation and safety management. Up until now, the industry has to some extent relied on personnel and their senses to navigate safely on the ocean. As we move toward full autonomy, these senses need to be replaced, including the auditory capability. From ferries to cargo ships and coastal freight transport, the ability to clearly understand auditory environments can dramatically improve operational effectiveness, reduce risks, and support the transition to autonomous navigation in maritime transport.