In the world of cybersecurity, ethical hacking proactively identifies security vulnerabilities before malicious actors (i.e., unethical hackers) can exploit them. By simulating real-world attacks, organisations can strengthen defences, protect sensitive data, and maintain public trust. In the physical security world, ethical hacking can transform cybersecurity of security systems from a reactive struggle into a strategic safeguard. We asked our Expert Panel Roundtable: What is the role of ethical hacking as it relates to physical security?

Next-generation (Next-Gen) technologies are products, services, or infrastructures that represent a significant leap forward rather than a small, incremental update. In the physical security industry, NextGen products are those that enable disruptive change, breakthrough performance, and a fundamental change that renders previous products obsolete. We asked our Expert Panel Roundtable: What is the next generation of physical security solutions, and how will they change the industry?

Emphasising proactive rather than reactive security shifts the focus from dealing with crises and damage control to prevention. Advantages of a proactive approach include cost efficiency, better business continuity, and fewer crises that draw attention away from strategic improvements. Staying ahead of threats is a core mission of the security department, and technology has evolved to enable security professionals to deliver on that mission better than ever. We asked our Expert Panel Roundtable: How are security systems transitioning from reactive to proactive, and what is the benefit?

Multiple technology trends are transforming the physical access control market. There is a fundamental shift away from physical cards and keys toward digital identities — mobile credentials, digital wallets, biometrics, and cloud-native access platforms. These next generation access solutions are radically reshaping how buildings operate, protect staff, and perform functionally. At the same time, AI and analytics solutions are being layered onto these physical access control systems to support predictive threat detection and behavioural insights. Access data itself is becoming an asset for sustainability, space optimisation, and smart building initiatives. Risk, impact operations and experience The annual HID Global Security and Identity Trends Report highlights these and other issues The annual HID Global Security and Identity Trends Report highlights these and other issues. The survey cites improving user convenience as a priority for nearly half of organisations, while 41% are focused on simplifying administration, and 28% struggle with system integration. These are not theoretical challenges, they are day‑to‑day friction points that add cost, increase risk, impact operations and experience, and, of course, must be addressed. HID Global’s commercial focus HID Global’s commercial focus is to help organisations digitise their access control — with mobile identities, biometrics, and cloud platforms — and then to use the data to deliver more value. “We are turning access control from an operational cost into a software-driven asset that improves efficiency, supports Environmental, Social, and Governance (ESG) goals and even creates new revenue opportunities,” says Steven Commander, HID Global’s Head of Consultant Relations. The impact of digital transformation Digital transformation is the method of moving access control from hardware and physical credentials Digital transformation is in the process of moving access control from hardware and physical credentials to a software-driven, integrated experience. The transformation strengthens security while also improving user convenience — transforming the “pavement to the desk” journey. HID enables this shift through mobile credentials, biometrics, cloud-native platforms, and solutions that allow third-party applications to run on door hardware. “This helps customers turn access data into operational and commercial outcomes, while also improving the overall user experience,” says Commander.  Digital transformation in access control is not focused on chasing the latest trends. Rather, transformation is about turning software, data and integration into outcomes that matter to customers, says HID. “Security becomes stronger and more adaptive,” says Commander. “Operations become simpler and more cost‑effective. Experiences become seamless and consistent. Sustainability moves from ambition to action. And the financial case becomes clearer as efficiencies are banked and new value streams emerge.” The challenge of futureproofing with long lifecycles Given that physical security technologies will be in place for 15 to 20 years, it is important to plan for how systems can evolve over time. Considering how rapidly security threats, compliance standards, and user expectations change, 15 to 20 years is a long time. The decisions made at the beginning of a system’s lifecycle can either limit flexibility later (which will be costly) or enable long-term adaptability. Support for open standards such as Open Supervised Device Protocol (OSDP) is therefore important Choosing products and platforms that are open, interoperable, and designed for updates can enable future-proof projects. Support for open standards such as Open Supervised Device Protocol (OSDP) is therefore important.  In addition, systems built on open controller platforms — such as Mercury — enable organisations to switch software providers or expand functionality without replacing core door hardware. Architectural openness is key to system lifecycles and maximising the return on investment (ROI) from a chosen solution. Digital credentials and mobile access Flexibility and upgradeability should also be top of mind when it comes to endpoints like access control readers. While RFID cards are still commonplace, there is a clear trend toward digital credentials and mobile access. Readers that support both allow organisations to transition at their own pace, without committing to a full system overhaul. A long system lifecycle does not mean technology should remain static. Security, particularly cybersecurity, demands more frequent updates. Technologies that support firmware upgrades in the field extend the value of a deployment while helping organisations keep pace with emerging threats. In that sense, lifecycle thinking is not just about longevity — it’s about maintaining resilience and readiness over time. Applying biometrics and mobile identities Biometrics is becoming mainstream as a credential alternative, strengthening security without adding friction Biometrics is becoming mainstream as a credential alternative, strengthening security without adding friction. Many organisations are now deploying biometrics to support fast, seamless access journeys, with adoption already around 39% in access control according to HID’s recent research.  In addition, 80% of organisations surveyed expect to deploy mobile identities within the next five years. Full technology integration enables tap‑to‑access without opening an app; the user journey becomes faster, safer, and more convenient. “It is where the industry is headed and we are at the vanguard of this,” says Commander.    Ongoing challenge of cybersecurity At HID Global, cybersecurity is embedded into everything, from corporate processes and development practices to the solutions they bring to market. “Our approach ensures that customers can strengthen their overall security posture, not only by deploying secure products but by benefitting from HID’s commitment to the highest industry standards,” says Commander. HID holds multiple globally recognised certifications, including ISO 27001, ISO 14298, SOC Type 2 and CSA STAR, which demonstrate their robust information security and cloud security practices. In addition, HID’s SEOS® secure chipset is independently SEAL-certified, providing one of the most advanced levels of protection available on the market today. “Ultimately, this means organisations are not just purchasing isolated secure products; they are implementing solutions developed and delivered within a comprehensive, cybersecure framework,” says Commander. “When deployed according to best practices, HID solutions enable customers to achieve the highest levels of resilience against evolving physical and cyber threats.” Developing green and sustainable solutions A huge amount of waste is generated from the manufacture of plastic RFID access cards Digital credentials align with the sustainable solutions that everyone wants. A huge amount of waste is generated from the manufacture of plastic RFID access cards. Over 550 million access cards are sold annually. This creates 2,700 tons of plastic waste and 11,400 tons of carbon, based on a PVC card weighing 5 grams.  Therefore, digital credentials self-evidently reduce the reliance on plastic cards (helping reduce carbon emissions by up to 75% according to HID’s research), while leveraging access control system data supports energy optimisation by shutting down or reducing systems in unused spaces. Energy use and CO₂ emissions can be cut dramatically, showing how access systems can contribute to sustainability goals and green building certification. What is the latest in smart buildings? Smart buildings increasingly rely on mobile access control as the backbone for digital services. Real-time access data enables new services such as automated room bookings, HVAC control, lift/elevator calling, e-bike hiring, and so on. Smart buildings increasingly rely on mobile access control as the backbone for digital services The financial upside is clear; smart, digitally transformed buildings can deliver around 8% higher yields per square foot versus traditional office space. Operational savings accrue from reduced administration, the removal of card production and shipping, and lighter IT support. This creates a value cycle — better experiences drive adoption, adoption fuels monetisation, and monetisation funds further improvements. Achieving technology impact in the real world One standout project is One Bangkok – a $3.9 billion mixed used development in Thailand – which demonstrates the scale of what can be achieved when access control data is used for optimisation, particularly when it comes to monitoring facilities usage and occupier behaviours. By switching lights off or lowering the temperature in unused rooms, for example, the One Bangkok building demonstrates this potential with a 22% reduction in energy consumption, saving 17,000 MWh and 9,000 tons of CO₂ annually.  Sustainability is a key factor in contributing to how properties are valued. And sustainability extends far beyond digital credentials having a lower environmental impact than plastic cards.  Buildings with recognised sustainability certifications often command rental premiums of around 6%, and three‑quarters of security decision‑makers now consider environmental impact in their procurement assessments.

HID, a worldwide pioneer in trusted identity and physical access control solutions, has launched HID Signo Décor in response to a request that architects, specifiers and integrators have repeatedly raised: a Signo-grade reader built for high-design spaces, without a compromise on the security behind it. The Signo Décor Reader 30 model mounts flush on European- and China-style back boxes and sits behind a robust glass face, rated IK10 for impact resistance and IP65 for indoor and outdoor use, fitting naturally into design-led lobbies, hotels, transport hubs and mixed-use developments while standing up to demanding daily use. Certified secure element hardware "Security should not force a choice between how a space looks and how well it is protected," said Jos Beernink, Vice President Europe for HID’s Physical Access Control (PACS) business area. "This belief is what drives HID's product development: to give customers choice without asking them to trade away the trust they have placed in our Signo line." Décor runs on the same architecture as the rest of the Signo family, so specifiers and integrators can bring it into a design-led project with the same confidence as any other Signo reader. It uses EAL5+ certified secure element hardware and supports SIO data model for trusted authentication, and it communicates with control panels over Open Supervised Device Protocol for encrypted two-way monitoring. Native Bluetooth and NFC support means end users can present a phone as easily as a card, using HID® Mobile Access® and digital wallet credentials alongside existing access cards. Consistent design language For teams managing readers across a portfolio of buildings, that consistency extends to operations. Signo Décor can be updated and monitored through HID Reader Manager, or remotely using HID Linq , so firmware and configuration stay current without a technician visiting every door. It is also available as a module for integration into intercoms, elevators, turnstiles and other access hardware, giving OEM partners a consistent design language across their product lines. The Signo Décor Reader 30 model, available in black or white in a 90x90 mm form, is available to order now in Europe, China, Hong Kong, Singapore and the UAE. Additional Signo Décor model variants will become available in other regions later this year.

Connected Technologies is partnering with Farpointe Data, San Jose, California, expanding Apple and Google Wallet credential support to include CONEKT® mobile-ready readers - delivering a solution that’s more cost-effective than most other NFC wallet providers. Mobile access control is becoming ubiquitous with secure physical identity management. The Connect ONE® wallet card solution utilises the phone’s native wallet app to help dealers migrate users to mobile credentials. NFC access badges “Going beyond just a competitive cost, Connected Technologies' integration with Farpointe's CloudCONEKT® benefits security integrators by deploying NFC access badges – Apple and Google, to end-users with a simple, quick, and repeatable solution that requires minimal planning,” said Francisco Alcala, North American Sales Manager, Farpointe Data. Connect ONE’s unified, intelligent cloud platform eliminates app downloads and physical badges. Wallet cards can be dealer-branded, so every access user sees the dealer’s company name/logo every time they use their credential. Existing customer infrastructure “Mobile credentials offer dealers a highly desirable way to attract and maintain customers while supporting new RMR opportunities,” said Dan Simon, Technical Director, Connected Technologies. “The partnership will enhance and expand the possibilities for dealers to deploy mobile credentials across a growing range of readers and manufacturers.” Connect ONE’s NFC Wallet Cards work with any access control system, preserving the existing customer infrastructure. With Connect ONE, dealers are not locked into a single reader manufacturer, giving them the flexibility to choose the reader that’s the best fit for the application. Connect ONE integrates with existing infrastructure to enhance capabilities without costly replacements, unifying access, video, intrusion, fire, and environmental systems into a single platform that improves visibility and streamlines operations.

Gunnebo Safe Storage has introduced OEM Barrier Solutions, a global offering bringing together its engineering, manufacturing and certification capabilities for security-critical applications. The launch builds on Gunnebo Safe Storage's established work with manufacturers across the financial sector, high-risk industries, high-end retail, pharmaceutical markets, reflecting the wider range of applications in which its barrier technology is now being integrated. Security-critical applications One in four ATMs worldwide incorporates a Gunnebo safe, providing a long-standing example of how its certified protection can be engineered into complex products and manufactured at scale. OEM Barrier Solutions supports manufacturers across security-critical applications, providing reinforced steel and composite-filled barriers alongside engineering, certification and manufacturing support. Its capabilities cover threats including burglary, fire, ballistic and electromagnetic protection, with region-for-region manufacturing helping OEMs maintain consistent production and reduce supply chain exposure. Certified barrier components Says Nathan Atterbury, Vice President, OEM Barrier Solutions at Gunnebo Safe Storage: “Our experience with OEMs has developed through years of working alongside manufacturers on products where the barrier cannot simply be treated as a standalone component. It works within the wider system, meets the required certification and continues to perform through production and operation. OEM Barrier Solutions brings our engineering experience, and proven security know-how together and gives us a clear platform to support manufacturers across a much broader range of security-critical applications.” Gunnebo Safe Storage can provide locking technology, authentication systems, software and connectivity alongside certified barrier components. These technologies can be incorporated into OEM product designs where physical protection and electronic security form part of the same system. OEM barrier solutions The breadth of engineering, certification and manufacturing capabilities can be applied wherever physical protection is incorporated into the design of other products, including those requiring integration with electronic security and connectivity systems. Nathan concluded: “With OEM Barrier Solutions, Gunnebo Safe Storage is bringing our capabilities together for manufacturers operating in environments where compliance, resilience and product integrity are fundamental to product development. The focus is on working with OEM engineering teams from the outset, supporting the product through certification and production, and maintaining a technical relationship throughout its lifecycle.”

Genetec Inc, the global pioneer in enterprise physical security software, is now inviting contributions for the 7th annual edition of its global State of Physical Security report. In 2025, Genetec’s survey received responses from over 7,300 participants across six continents, offering valuable insight into emerging trends within the industry. The report found that interest in adopting AI has more than doubled among end users since the previous year. Additionally, security is increasingly being used as a strategic enterprise function, with systems delivering valuable business intelligence alongside protection of people and premises. Strategic enterprise function Guy Rushworth, Enterprise Account Executive, Genetec, says “Our Physical Security report gives us a direct line to the people actually running security operations day to day – end users, integrators, and consultants. This feedback doesn't just shape our own thinking; it helps the whole industry understand where the real challenges are, and where physical security is headed next. We'd encourage as many people as possible to take part and add their voice." The survey takes approximately 10 minutes to complete, and all responses remain anonymous. Participants have until 21st September to take part, and will receive early access to the final report plus entry into a random draw for one of eight £500 Amazon gift cards.

The Honourable Society of Lincoln’s Inn is one of the four Inns of Court and operates as an active and thriving society of lawyers, sprawling across 11 acres in central London and dating as far back as 1422. The title of “Lincoln’s Inn” refers both to the Society and the location, which houses the Society’s own facilities, numerous barristers’ chambers and several solicitors’ offices. The Inns of Court originally provided accommodation for law students who learned their craft by attending court. Different levels of security Today, the Inns exist to aid students in pursuing the legal profession and serve as landlord, custodian of historic buildings, banqueting and events venue, and tourist attraction. To fulfill these many functions, Lincoln’s Inn required security that would meet their own high standards while protecting buildings that had been in continuous operation for centuries. As the Inn not only provides services to law students, but also operates as an attraction and a hosting venue, many different levels of security need to be in place for a variety of users—full-time employees, temporary contractors, event staff, students, and others. For this reason, it was essential that Lincoln’s Inn have a comprehensive system to track and monitor their many keys for the extensive venue. Improving key control For some time, keys at Lincoln’s Inn were managed manually through an analogue system, with staff retrieving keys from an open cabinet and recording key usage with pen and paper. However, because at times manual recordkeeping can be less than diligent, this allowed for confusion as to who had what keys when, and made it possible for keys to be stashed away or used by unauthorized persons. With the variety and quantity of people moving throughout Lincoln’s Inn on any given day, a more secure solution was needed. To update and improve key control, Chief Porter Nicholas Bracey turned to the KeyWatcher Touch key control system by Morse Watchmans. Key storage and management “KeyWatcher Touch provides us with a fully secure means of key storage and management. We considered a number of products on the market and found the Morse Watchmans solution to be the most flexible and easy to use system,” said Mr. Bracey. “The high quality and ease of scalability were two of the top features we required, and the KeyWatcher Touch was a perfect fit for our key control needs.” Lincoln’s Inn installed two KeyWatcher Touch units configured for a total of 192 keys or keyrings in January 2016, and the system has been in daily use since the installation. It utilizes the Inn’s IT network and is fully integrated with the PCs in the security office and the office of the Chief Porter in order to provide maximum flexibility and ease of use. Providing maximum flexibility Tracking keys as they were removed and returned was a top concern, so the ability of the KeyWatcher to record who has removed what key and when was exceptionally important. “The keys are always secure, rather than being openly accessible to staff. There is no longer paperwork to be managed for logging, it is all taken care of with the KeyWatcher software,” continued Mr. Bracey. “Audits and reports are fast and accurate, and it has led to our staff becoming more responsible overall.” KeyWatcher Touch has provided Lincoln’s Inn with the functionality and security it requires to easily manage its 192 keys, while also providing an easily accessible audit trail. In addition, the system has proven hardy and resilient in daily use over two years. “We have had continuity with Morse Watchmans since day one,” finished Mr. Bracey. “Demonstrations of function, installation, and training were all handled almost entirely by the same representative, in addition to subsequent orders. The continuously exceptional service has ensured that we were getting exactly the product that would best serve Lincoln’s Inn and provide us with the security we need.” KeyWatcher Touch Features: Email and SMS Notifications Scheduled Reports via Email or SMS Centralised User Database Scalable, Modular Design

Genetec Inc., the global pioneer in enterprise physical security software, announces that TEPCO Power Grid has deployed Genetec™ Security Center as the foundation for a next-generation physical security platform that supports its broader digital transformation strategy and scales with its growing operational requirements. The platform will centralise management of more than 30,000 cameras and support future innovation across the TEPCO Power Grid network of 1,600 substations and service centers. TEPCO Power Grid manages and operates the transmission and distribution network that delivers electricity from power plants to homes and businesses across the Tokyo metropolitan area. The company is using advanced technologies to improve operational efficiency, strengthen disaster response, and modernise critical infrastructure. Modernising critical infrastructure As its camera network expanded over the years, TEPCO Power Grid needed a platform capable of supporting large-scale camera management, integrating with image analysis technologies, and expanding access to video across a broader range of devices. After evaluating several options, the company selected Genetec Security Center for its functionality, scalability, proven track record, and customisation capabilities through its software development kit. “The response from users has been very positive, and we're already seeing new ideas emerge for how the system can be used across the organisation. Beyond supporting our current operations, we see an opportunity to leverage accumulated video data alongside AI technologies to support future operational and technology initiatives, and we look forward to continuing our collaboration with Genetec,” said Tomoyuki Soma, Group Manager, System Development General Affairs Group, System Development Center, DX Promotion Department, TEPCO Power Grid. Improving operational efficiency TEPCO Power Grid selected Security Center for its scalability and open architecture. The platforms broad camera support allowed the company to bring together camera models from multiple manufacturers into a unified environment, helping preserve existing hardware investments while giving teams room to evolve. The Security Center software development kit also enables the company to customise the system and integrate additional technologies as requirements evolve. Security Center gives TEPCO Power Grid a unified view of its camera network while allowing teams across the region to support sites in their respective areas. Activities such as adding cameras and updating maps, which were previously managed centrally, can now be performed by individual workplaces, helping improve operational efficiency. Digital transformation strategy Authorised personnel can also use the Security Center web app to view video from computers and mobile devices. During an incident or emergency, managers and field teams can remotely assess the situation and coordinate their response. The platform also helps teams identify camera malfunctions across the network, making it easier to locate and address issues TEPCO’s 1,600 geographically dispersed sites. In addition to video management, the company sees potential opportunities to leverage accumulated video data and integrate emerging technologies as operational requirements evolve. The company is also evaluating additional capabilities available within the Security Center platform as part of its longer-term digital transformation strategy.

In a sector where budgets are always a focus of attention, delivering concrete returns to every investment is crucial. By digitalising access, healthcare premises – whether large hospitals or small clinics – can benefit from day one. They can improve staff and patient safety; quickly implement more efficient, time-saving workflows; and painlessly meet compliance demands. Healthcare sites always present complex access challenges. They must be welcoming, accessible public spaces. They often occupy large, sprawling areas; unfamiliar faces and first-time visitors are around every single day. At the same time, these premises inevitably have valuable and/or sensitive assets, including confidential data and medicines, which must be secured. Patients, doctors, nurses and support staff must feel safe. In labs and treatment suites, restricted materials and valuable equipment need both security and a compliant system for logging every access event. This has always been healthcare’s ‘business-as-usual’: it is a complex environment for any security manager. Meeting compliance demands Modern hospitals and clinics, however, now face an extra level of challenges – and opportunities. Their access system may benefit from integration with fire detection, CCTV and other building solutions, for example. With so many temporary and contract workers employed on-site, access is in constant motion. It needs to be tailored to specific and very different needs and, equally, revoked when any time-limited tasks are complete. In case of a security breach, rapid investigation is essential. Tracing and logging access to specific areas may also be a legal requirement, especially with new NIS2 regulations introduced for critical infrastructure, which demand proactive “hybrid” cyber/physical security frameworks for many healthcare premises. Relying on manual or siloed systems to complete these tasks could eat up hours or even days for security and even medical staff. Happily, there is a better way to work. Digital access devices The solution is access digitalisation. Digital access devices and credentials help to keep every hospital user safe. Unauthorised access is minimised because unapproved key copies rarely circulate and lost credentials are cancelled with a click. Employees and equipment are safer because more access points may be digitally secured. Issuing contractors and temporary staff with digital or even mobile credentials can further simplify the granting, amending and revoking of site access. Security teams waste less time handing out and collecting keys. Intelligent, intuitive software helps facilities managers stay in control even while they are off-site. Logging access to specific assets or areas becomes quick and simple: a few clicks rather than the laborious process of keeping manual logs up to date. “Access is such an important part of any holistic approach to safety,” says David Moser, SVP and Head of Digital Access Solutions at ASSA ABLOY Opening Solutions EMEIA. “Digitalising access immediately puts powerful tools in the hands of hospital management, delivering tangible daily benefits to meet security challenges head-on, improving efficiency and regulatory compliance at the same time.” Implementing digital access “There’s now a device to extend existing systems with digital control at almost any access point, whatever building solution is in place. Alternatively, we can equip customers with whole solutions to implement digital access from scratch, without invasive installation. So many efficiency and security benefits are within reach.” Below are three of many real-life examples which illustrate the ways healthcare premises have benefited from digital access beyond the most obvious security and safety aspects. By choosing ASSA ABLOY’s Aperio® wireless locks, integrated natively with an ARD access management solution, Centre Hospitalier Métropole Savoie (CHMS) could issue access rights tailored to individual staff and contractors and implement real-time control, helping to boost site safety. Because Aperio locks are wireless, the hospital introduced more layers of security without incurring excessive installation or operating costs, including for sensitive offices and drug stores. Access point functionality at CHMS now includes real-time management logs and remote door opening. Real-time management logs For convenience, staff now carry one credential programmed with their individual tailored permissions. “Having just a single badge, and not having to carry around heavy keys, has been a major advantage for us,” explains Béatrice Dequidt, Health Executive at CHMS. “We have implemented internal HR management procedures, creating badges that are automatically integrated into ARD's operating software,” adds Alain Gestin, CHMS’s IT Systems Architect. Aperio and ARD maintain compatibility of credentials with the French government’s electronic Health Professional Card (CPS), for added staff and management convenience. Personalised access permissions Hospital MAZ, in Zaragoza, also implemented a new ASSA ABLOY digital solution, SMARTair®, with real-time access functionality. Their online wireless access management system saves security managers’ time because they can implement all changes via the central system in real time, without needing to waste time walking through the hospital. Staff convenience is further enhanced: they now carry a smartcard programmed with their personalised access permissions. Custom-made cards double as employee IDs, so 625 staff and approximately 100 contractors only need to carry one. Their ASSA ABLOY system is also mobile access ready, making it easy for the hospital to issue and manage mobile keys in the future without hardware changes. “Digitalisation presents opportunities for healthcare organisations of every size and type to improve security while they also reduce costs ‘hidden’ in daily workflows,” explains David Moser. Convenient secure access Managing physical keys can impact nursing care, as pharmacy managers at Queen Elizabeth Hospital, Birmingham discovered. An older, mechanical system made it difficult for them to keep track of who held the right key. Searching for that person wasted time. They identified a better solution for convenient secure access to controlled medicines: programmable keys. With their CLIQ programmable key access solution, power to digital and electromechanical locks is supplied by a standard battery inside every key, so no wires are required – making it an ideal retrofit solution for hospital doors, cabinets and mobile drug trolleys. Audit trails for locks and padlocks are available on demand: nurse managers can quickly see who has accessed cabinets or drug trolleys. Key access solution “The message from all nursing staff is that patients are getting medicines much easier and in a more timely fashion,” says Inderjit Singh, Chief Pharmacist at QE Birmingham. “For us, the key return on investment is the quality of service we’re providing.” “Our expertise in access, established over decades, enables us to work with customers to get their access ready for what’s ahead,” adds David Moser. “With ASSA ABLOY, they digitalise with confidence.”

Metallic, highly reflective surfaces are among the most challenging objects to inspect in machine vision applications. Reflections obscure details, defects often only become apparent from certain angles, and the quality of manual visual inspections varies throughout the working day. The Austrian company Danube Dynamics, in collaboration with EVVA, a manufacturer of mechatronic access solutions, demonstrates how these challenges can be managed with an AI-supported testing system. The system captures components placed in an orderly manner in a box in one step, automatically assesses surface defects, and integrates quality control reproducibly into the production process. Strict quality specifications Background: Challenging surfaces, high requirements - At EVVA, metallic components undergo several process steps and must meet strict quality specifications. These include, among others, locking cylinders, cylinder cores, and other finely machined or galvanised precision parts from access technology. Mechanical defects such as scratches under 0.1 mm and galvanisation errors must be detected – deficiencies that are often hardly visible to the naked eye. The central difficulty: Highly reflective surfaces reflect light and may conceal relevant features. For a reliable assessment, multiple viewpoints are often necessary. In practice, this complicates maintaining a consistently high quality of manual inspections. A solution was sought that reliably detects defects, supports employees, and integrates stably into the production process. Mechanical locking cylinder with a high-precision metal surface – test object of the AI inspection. Solution: Closed test box, coordinated lighting, AI To reliably solve these challenging inspection tasks, an AI-powered inspection system was developed in collaboration with Danube Dynamics. AI-powered inspection system The system captures components arranged in a 400 × 300 mm Eurobox in one step, automatically assesses surface defects, and integrates quality control reproducibly into the production process. Up to 126 components are arranged in the box and are tested in one pass. To 1/4 create constant conditions despite reflections, a closed test box with customised lighting is employed. Four individually controllable RGBW bars allow for different colours and lighting angles to make various defect patterns visible. The coordinated interplay of lighting, image quality, and AI evaluation was crucial. AI-based Inspection System: Arranged components in the Eurobox during optical inspection. The image capture is performed by a monochrome industrial camera of the type IDS uEye U3-36P0XCP-M GL Rev. 1.2. It is based on the 19.80 MP sensor AR2020 from onsemi, delivers 5K UHD resolution with 5136 × 3856 pixels, and is suitable for inspecting the finest surface details. High-contrast representation The 1/1.8-inch rolling shutter sensor in a 4:3 aspect ratio supports detailed imaging of even the smallest defects. The system is complemented by an IDS lens with a focal length of 8.5 mm (Type 20M11-C08528). “For us, it was crucial that we could capture many arranged components on a large testing area in one step while still reliably detecting the smallest surface defects. Only the interplay of lighting, high-resolution image capture, and AI evaluation makes this quality control robustly manageable,” underlines Edwin Schweiger, Co-Founder and COO at Danube Dymamics. The camera captures the entire Eurobox in high resolution. The image data obtained in this manner enables the detection of the smallest defects in each individual component using AI subsequently. What is crucial is not only the pixel count but also the repeat accuracy under defined lighting conditions. The monochrome version additionally supports a high-contrast representation of relevant surface features. AI detected deviations “Especially with highly reflective surfaces, it is essential to depict fine differences stably and in detail,” emphasises Jürgen Hejna, Product Owner 2D Cameras at IDS. “The camera's high sensor resolution and easy integration provide a solid foundation for industrial applications.” Ease of integration was also a decisive factor for Danube Dynamics. The camera can be integrated into the overall system via a standard interface. This reduces the development effort and ensures stable testing results during ongoing operations. Measurable benefit - The potential of the solution became evident during the first live deployment: The AI detected deviations that even experienced professionals hardly noticed. Above all, the significantly reduced testing time made the benefit immediately measurable. The previously manual visual inspection of more than 30 seconds per Eurobox has been reduced to under five seconds. The basis for this consists of four defined lighting scenarios, from which four images per component are generated. Subsequent AI inference The subsequent AI inference occurs with a runtime of approximately 10 milliseconds per cylinder. At the same time, the testing process has been fully digitised. Testing results are now systematically documented and statistically evaluated. Scrap and deviations that were previously not recorded are now transparently traceable. Manual quality control is therefore not replaced but specifically supported. Employees are relieved, testing processes are reproducible, and quality is measurably integrated into the production process. Another milestone is the ability to retrain the AI independently. EVVA can integrate new product variants and error patterns into the system by itself. This enhances the future viability of the solution and allows for adjustments to growing requirements without altering the fundamental system structure. AI-based evaluation The demands for automated quality control are increasing. At the same time, awareness is growing regarding what is possible with coordinated image capture and AI-based evaluation. While standard applications are relatively simple to implement today, this project demonstrates the potential in the inspection of demanding surfaces. It illustrates how even optically challenging, safety-relevant components can be reliably inspected using lighting, high-resolution camera technology, and AI. Customer - Danube Dynamics Embedded Solutions GmbH is a technology company based in Linz, Austria, which has specialised in intelligent embedded system solutions for industry since 2020. The company develops tailor made solutions at the interface of software, AI and electronics with the aim of driving automation and digitalisation forward in an efficient, secure and future-oriented manner through "AI at the Edge". Mechatronic access solutions Today, Danube Dynamics has over 30 customers across Europe and employs a team of more than 15 highly qualified developers and engineers. For over 100 years, EVVA has been synonymous with mechanical and electronic access systems at the highest technical level. What began in 1919 with the founding of the ‘Invention-Testing-Utilisation-Institution’ (EVVA) is now a central part of the company philosophy: EVVA conducts its own research, develops and produces independently, and realises innovative mechatronic access solutions. As a family-owned business, EVVA is among the most successful companies in the industry internationally: Over 300 patents have been registered; subsidiaries in ten European markets and worldwide distributors ensure international presence.