# Can Roll-2-Roll sensors detect splices, flags, and surface defects?

> Yes. Because each Roll-2-Roll® sensor is a linear imaging array — not a point sensor — it sees the full profile of the web at capture rates up to 1,000 Hz.Tape splices, operator flags, tears, and voids all change that profile in detectable ways. The sensor and controller identify these changes in...

**Last updated:** 2026-03-14

**Source:** https://live-roll2roll.pantheonsite.io/resources/faq/can-roll-2-roll-sensors-detect-splices-flags-and-surface-defects

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## Question

Can Roll-2-Roll sensors detect splices, flags, and surface defects?

## Short Answer

Yes. The sensor spatial awareness across its full pixel array enables real-time detection of splices, flags, tears, voids, and other surface anomalies without additional hardware.

## Detailed Answer

Yes. Because each Roll-2-Roll® sensor is a linear imaging array — not a point sensor — it sees the **full profile of the web** at capture rates up to 1,000 Hz.

Tape splices, operator flags, tears, and voids all change that profile in detectable ways. The sensor and controller identify these changes in real time:

- Splice detection — tape splices and overlaps create a measurable change in the web profile that triggers an alert or output signal
- Flag detection — operator-placed flags and registration marks are detected across a wide sensing window (up to 48 mm for mark detection vs. 2–8 mm for conventional sensors), significantly reducing setup sensitivity
- Tear and void detection — holes, tears, and missing material show up as gaps or profile changes across the pixel array
- Thread and string counting — individual threads are resolved and counted using the sensor resolution (as fine as 0.0635 mm)

The same sensor-controller combination handles these inspection tasks alongside edge guiding or width measurement — no second system, no additional hardware required.

**Category:** Technical

## Related Products

- [ODC 96](https://live-roll2roll.pantheonsite.io/products/sensors/odc-96)
- [1DC 96](https://live-roll2roll.pantheonsite.io/products/sensors/1dc-96)

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## About Roll-2-Roll Technologies

Roll-2-Roll Technologies designs and manufactures patented fiber-optic web position sensors and advanced web guiding controllers — the precision measurement and control core of modern roll-to-roll manufacturing. Spun out of Oklahoma State University's Web Handling Research Center and trusted by Fortune 500 medical, battery, and nonwovens manufacturers, our patented sensors work without recalibration at ±0.1mm accuracy up to 760 mpm — typical customer outcomes are 50%+ less downtime and payback under six months. Headquartered in Stillwater, Oklahoma, our team of PhDs, controls engineers, and industry veterans extends the sensor + controller core into complete web guide systems including stepper-motor-based linear actuators (RLA, BLA, LHS).

- Website: https://r2r.tech
- Phone: +1 (888) 290-3215
- Email: sales@r2r.tech