AI-Powered Workpiece Recognition in CNC Machining

Use Case:

Implementation of a vision and AI-driven workflow to automate workpiece recognition and alignment in CNC machining improving setup accuracy reducing human error and enabling scalable integration with existing systems.

Outcome:

Automated high-resolution image acquisition and workpiece database creation; AI model for identifying geometric features and small-scale details with high accuracy; 50% reduction in alignment time compared to manual probe-based procedures; Scalable solution ready for integration and industrial testing; Agile development of a business model for internal use and future commercialization.

Ecosystem Support:

StairwAI project support; technical mentorship for feasibility planning and AI adoption strategy; facilitated access to experimentation and expert feedback.

AI Relevance:

This success story demonstrates AI democratization for SMEs by: I) applying machine vision and lightweight AI to legacy manufacturing processes; II) enabling measurable performance gains (speed, precision, safety); III) lowering barriers to AI adoption through modular software and clear integration paths; IV) validating a roadmap for transition from internal adoption to market-ready product.

Summary:

IMOLD SRL, a company active in mold and die manufacturing, aimed to tackle the inefficiencies of manual setup and alignment in CNC machining. Through the StairwAI program, they developed WRRA in CNC, a workflow based on AI and image recognition to detect and align workpieces with high precision. The solution comprises three key modules: image acquisition and database generation using a high-resolution camera; AI-powered feature recognition of workpieces including geometry and obstacles; and automated probe-based validation of workpiece position in the CNC reference frame. Notably, the new AI-assisted system is expected to reduce alignment time by 50% and improve safety and reproducibility. IMOLD’s strategy initially focuses on internal deployment, with long-term plans to commercialize the solution across a broad CNC manufacturing ecosystem, including machine tool vendors and industrial workshops. With mentorship from StairwAI, the company successfully delivered both a technical feasibility plan and a business model canvas, validating the relevance and potential of AI integration in this critical manufacturing stage.