Uncovering Hidden Details: CT Scanning an Albuterol Inhaler with Advanced Mixed Material Artifact Reduction

The Need for High-Precision Scanning in Medical Device Manufacturing

Medical devices demand uncompromising precision. Whether it’s an albuterol inhaler, a syringe, or an implantable device, quality control is non-negotiable. Even the smallest defect can compromise function, patient safety, or regulatory compliance. That’s where industrial CT scanning becomes a game-changer—offering insight into the internal structures of complex assemblies without disassembly or destruction.

At Nel PreTech Corporation (NPC), we recently scanned an albuterol inhaler using advanced X-ray computed tomography (CT scanning) at a 77.65-micron voxel resolution. The results? A fully intact digital reconstruction that reveals every internal mechanism, from aerosol pathways to micro-valves, in stunning clarity. Let’s explore why resolution settings, material complexities, and cutting-edge scan enhancement techniques matter when it comes to medical device quality assurance.

The Importance of Resolution in Industrial CT Scanning

When scanning medical devices, resolution plays a crucial role. The level of detail in a CT scan is determined by voxel size. A voxel represents the three-dimensional equivalent of a pixel. Imagine voxels as tiny building blocks—just like pixels create a digital image, voxels stack together to form a 3D representation of an object. The smaller the voxel size, the more detail is captured, allowing for higher precision in identifying potential defects or material inconsistencies.

• High-resolution scans capture intricate details crucial for defect detection and performance validation.
• Lower resolution scans can provide a broad overview of a part’s structure, serving as an effective first step in an investigation. In some cases, a basic, low-resolution image is sufficient to highlight potential areas of concern before investing in higher-resolution scans, offering a cost-effective approach to initial assessments.

Different resolutions are selected based on the material density and complexity of the part being analyzed. For instance:

• Steel, with a density of approximately 7.85 g/cm³, requires higher energy X-rays and optimized resolution settings to penetrate without excessive attenuation.
• Plastics, with densities typically ranging between 0.9 and 1.4 g/cm³, are much less dense, meaning lower energy X-rays can often provide sufficient detail without needing to sacrifice resolution due to power constraints.

By adjusting the resolution to match the material properties, Nel PreTech ensures that scans achieve the right balance of clarity, efficiency, and cost-effectiveness for every medical device analysis.

‍Scanning Mixed Materials: Overcoming Challenges with AMMAR Technology

‍One of the biggest challenges in CT scanning is handling multi-material components, especially when high-density materials like steel are combined with lower-density materials like plastic. Traditional CT scans often suffer from artifact distortions, making it difficult to obtain a clear and accurate representation of both materials in a single scan. To combat this, we used AMMAR (Advanced Mixed Material Artifact Reduction) by Zeiss. This state-of-the-art technology can minimize distortion and enhance the clarity of both metallic and polymer-based components. This breakthrough allows for:

✅ Clear visualization of fine plastic features without metal-induced shadowing.

✅ Accurate defect detection in steel components without interference.

✅ Enhanced contrast and resolution, ensuring high-precision data for quality assurance and compliance checks.

Why Medical Device Manufacturers Need Industrial CT Scanning

For medical device manufacturers, CT scanning offers benefits that go far beyond simple imaging. The ability to inspect devices non-destructively means:

🔹 Regulatory Compliance – Ensuring adherence to FDA and ISO standards.
🔹 Failure Analysis – Identifying micro-defects before they lead to recalls.
🔹 Reverse Engineering – Digitally reconstructing parts for design improvements.
🔹 Manufacturing Validation – Confirming precision in mass production.

With CT scanning, hidden defects become visible, ensuring that every inhaler, syringe, or implantable device meets the highest standards before reaching the market.

Why Choose Nel PreTech for Medical Device Scanning?

At NPC, we specialize in high-precision industrial CT scanning services tailored for medical device manufacturers. With advanced Zeiss CT technology, cutting-edge artifact reduction techniques, and decades of expertise, we provide:

✔️ Ultra-high-resolution scanning for defect detection & quality control.
✔️ Expert analysis for complex mixed-material components.
✔️ Regulatory-compliant reports to support industry standards.

💡 Need absolute precision in your medical devices? Contact Nel PreTech today for a consultation and see how industrial CT scanning can revolutionize your quality control process.

By leveraging cutting-edge CT scanning technology, Nel PreTech continues to set the standard for precision, quality, and seeing beyond the surface.