How Antenna-I Is Bringing AI-Powered Quality Control to Sensor Manufacturing

Tackling Antenna Defects with Affordable, AI-Driven Precision

Maintaining consistent quality in IoT sensor production is a growing challenge—especially for small and medium-sized manufacturers handling diverse product lines and low-to-mid volume output. Traditional antenna testing methods like anechoic chambers or radiation pattern scanners are not only expensive but also impractical for SMEs operating on lean budgets. To address this, Correlation Systems launched Antenna-I under the AI REDGIO 5.0 framework—a compact, low-cost, AI-powered quality control system tailored for edge deployment. Piloted at their Czech production facility, Antenna-I replaces error-prone manual inspection with AI-at-the-edge to verify antenna-to-sensor assembly in real time. The system uses ESP32-based WiFi receivers to capture the radiation pattern of each sensor and compares it to expected profiles using dedicated machine learning models. Antenna-I is built around two core AI models: one for automated antenna type recognition, and another for evaluating assembly quality. With support for multiple antenna types and requiring no more than ten ESP32 receivers, the system achieves over 90% prediction accuracy within a 3 dB tolerance, all at a unit cost below €150. This is a game-changer compared to conventional testing solutions costing thousands of euros. Unlike vision-based inspection systems, Antenna-I does not rely on lighting, cameras, or physical markings. Instead, it focuses directly on RF performance, making it more robust, lightweight, and versatile in varying production conditions. The models require minimal training (under 30 minutes per antenna type), are easy to use even for non-experts, and deliver results in under 5 minutes at the edge.

A Step Toward Smarter, Sustainable Manufacturing 

As the IoT industry scales, so do expectations for reliability, efficiency, and sustainability in device production. Yet many manufacturers, particularly SMEs, lack the resources to implement high-end automated systems. Antenna-I fills this gap by offering a scalable, edge AI solution that delivers enterprise-grade quality control without the associated complexity or cost. By combining open hardware with intelligent algorithms, Antenna-I enables manufacturers to detect antenna issues before products ship, reducing return rates, warranty costs, and reputational risk. Incorporating edge AI for hardware-level quality assurance isn’t just an innovation—it’s a strategic move. Antenna-I helps bridge the digital divide in manufacturing, empowering even the smallest teams to take a decisive step toward Industry 5.0: smarter, human-centric, and data-driven production.