If you’re responsible for welded assemblies, you don’t just want parts, you want proof. Since 2024, ATACO Steel Products Corporation has operated an in-house Cut & Etch (macroetch) laboratory to document weld quality for demanding applications. Now, we’ve raised the bar again with 4K, 3D digital microscopy: a Keyence VHX-X1 4K digital microscope, a system that delivers sharper images, faster analysis, and tighter traceability than conventional tools.
A Clearer Picture of Weld Quality
Traditional microscopes can leave room for uncertainty, especially when dealing with thick sections or reflective metals. The new Keyence system changes that. True 4K resolution combined with a wide depth of field makes fusion lines and heat-affected zones stand out clearly, even on complex fillet welds. Surface imperfections such as pores, toe cracks, or lack-of-fusion are brought into sharp focus through advanced shadowing techniques that create an SEM-like visualization. That clarity eliminates guesswork and provides weld evidence your quality team can act on.
Stainless steel and aluminum, often difficult to evaluate under bright light, are no longer a challenge. Automated glare control and HDR lighting produce images free of blown highlights or muddy shadows. Combined with depth composition technology, engineers can view fully focused, wide-area cross-sections in a single frame. The result is a comprehensive and reliable view of weld integrity from every angle.
Repeatable Results, Traceable Evidence
Documentation is often as important as the weld itself. The Keyence system captures calibrated 2D and 3D measurements of penetration, throat, and reinforcement, with all magnification and settings stored alongside the image files. Every report becomes audit-ready evidence for PPAP submissions or customer reviews.
The repeatability of the system is equally valuable. With “replay” recipes, optics and lighting conditions can be locked in and reused across multiple inspections. That consistency is ideal for control plans, capability studies, and ongoing production checks where comparisons over time are critical. Larger samples can also be accommodated, and measurements can be repeated at the exact same coordinates to ensure truly apples-to-apples evaluations.
Faster Launches, Fewer Handoffs
Because the microscope sits inside our Cut & Etch Lab, directly adjacent to our welding and fabrication cells, projects benefit from faster decisions and less back-and-forth. Engineers don’t have to wait for outside lab results or schedule additional reviews. Questions can be answered on the spot, keeping prototypes moving and reducing surprises when programs transition to full production. Paired with our welded assemblies, 3D 5-axis laser cutting, and precision metal fabrication services, OEMs gain a single source that keeps quality and production under one roof.
Built for Production Reality
Our customers build equipment that works hard: construction machinery, off-highway vehicles, agricultural equipment, and defense systems. For those industries, weld quality isn’t theoretical. It determines whether parts survive real-world conditions. With our expanded lab, customers can expect PPAP-ready documentation that combines crystal-clear imagery with actionable pass/fail criteria. That feedback doesn’t stop at the report, either. Results are shared directly with our welding, fabrication, and machining teams so improvements can be applied immediately, often showing up in the very next part.
Deep-drawn shells and heavy stampings also benefit from this level of validation. Quantifiable penetration and fusion data are captured before assemblies ever hit the field, providing confidence that critical structures are built to withstand demanding use.
What Customers Receive
A typical weld validation package from ATACO now includes:
- Annotated macro images of etched cross-sections in 4K resolution
- Measured penetration and bead geometry in calibrated 2D/3D formats
- Timestamped, digital records stored for audits and future reference
- A clear pass/fail summary aligned to your specification
The Bottom Line
For OEMs, the new microscope strengthens three priorities: confidence, speed, and value. Calibrated, repeatable measurements confirm weld integrity for critical assemblies. On-site testing keeps projects moving without the delays of an outside lab. And by eliminating external testing fees, ATACO can reinvest in technology and process control, delivering consistent quality at a competitive cost.
Ready to Validate Your Next Weldment?
Include macroetch testing in your next RFQ. Our in-house CWI will work directly with your team to ensure all required weld and quality standards are met.
