Comet Technologies has detailed Dragonfly 3D World 2027, the next release of its CT image analysis software, adding AI-assisted segmentation, a new quantitative porosity measurement method, and a surface roughness tool that works directly from CT scan data.
The release's instance segmentation workflow is built on Meta AI's Segment Anything Model. A single click identifies and separates an object in a 2D view, creating individual labels without manual outlining or a dedicated trained model. For CT inspection, that applies to features such as pores, inclusions, weld defects and particles inside battery components. A related tool, Fast Split, uses Dragonfly's GPGPU framework to separate touching objects faster than the software's existing watershed method, aimed at datasets with closely spaced pores or particles.
The bigger change for quantitative work is Subvoxel Multi-Mesh. Instead of treating a connected structure as one voxel-based region of interest, the software separates individual pores, voids or phases into independently labeled surface meshes and measures each one on the mesh surface rather than the segmentation result. According to Comet Technologies, this produces subvoxel accuracy and supports repeatable analysis across CT datasets, useful for casting porosity analysis and battery component inspection. Engineers doing repeat CT porosity studies will care about that repeatability claim more than the AI segmentation headline.
Surface Roughness Analysis is the other notable metrology addition. It performs one-dimensional profile and two-dimensional areal roughness measurements on CT-derived meshes, giving a non-contact alternative to stylus profilometers for surfaces that are hard or impossible to reach physically, including internal geometries. Potential applications include additive manufacturing inspection, machined component measurement and tribology studies. The Surface Determination tool behind it has been redesigned with histogram-guided thresholding.
The release also adds Boolean mesh operations, automatic scan-to-CAD registration, STEP import, and a Report Builder that exports PDF and HTML reports. Full License holders additionally get editable Microsoft Word export, customizable headers and footers, and embedded 3D surface meshes.
Subvoxel Multi-Mesh, Surface Roughness Analysis and the extra Report Builder functions are Full License features only. The release also adds the ability to export ORSObject and ORSSession files, viewable through a free Project Viewer. A separate Session Viewer application, planned for later in 2026, will let colleagues without a full license open and interact with those shared files directly.
