Will Jones
In the world of heavy manufacturing, some of the most critical jobs still depend on processes that haven’t changed much in decades. Shipyards, infrastructure projects, energy systems, and defense work all rely on skilled welders, yet quality control in these environments remains largely reactive. Sophia Millar, co-founder and CEO of Sonibel Instruments, saw an opportunity to change that. After building experience in finance and early-stage software startups, she moved into hardware to tackle one of industrial production’s persistent bottlenecks.
From Finance and Fintech to Deeptech Hardware
Millar started her career in public equities research in Toronto. She then took on broad operating roles at small startups, including Corgi Labs, a Y Combinator-backed fintech company. During her final year at the University of British Columbia, she met engineers George Hollo and Hooman Pirouz in an entrepreneurship class. Together they spoke with more than 250 fabricators and kept hearing the same challenge: welding defects that are only discovered after the fact, driving up costs and delaying critical projects.
A Practical Solution for Real-World Welding
Sonibel Instruments developed a torch-mounted acoustic sensor that listens to the sound of the welding arc. Machine learning models analyze that audio in real time to spot defects like porosity, lack of fusion, or lack of penetration while the weld is still being laid. The goal is simple: give welders and quality teams immediate feedback so they can correct problems on the spot instead of dealing with expensive rework later.
The system is built first for human welders in common semi-automatic setups. Unlike many camera-based alternatives, Sonibel’s system performs well in the smoky, variable conditions typical of real fabrication shops.
Sonibel is Gaining Traction
Since graduating, the team has moved quickly. Sonibel closed an oversubscribed $1.6 million pre-seed round led by Maple VC, with participation from Champion Hill Ventures, Dorm Room Fund, and strategic angels. The company is running a pilot with a Fortune 100 customer, fielding interest from other major fabricators, and expanding its team beyond the three founders. It also graduated from the Creative Destruction Lab.
Millar leads the company as CEO, overseeing product development, fundraising, and its push into the U.S. market. The team incorporated in Delaware to better serve American customers and is focused on expanding pilots and making the sensor easier to deploy.
Tackling Legacy Challenges in Manufacturing
Sonibel’s work sits within growing interest in applying AI directly to physical industries. As demands on manufacturing capacity continue, tools that provide real-time insights on the factory floor are gaining traction. Welding serves as Sonibel’s initial focus, with plans to expand the platform to address additional quality and efficiency needs in industrial environments.
Millar’s move from software and finance into industrial hardware shows one way founders are approaching opportunities in this space. Her company offers a practical example of startups developing targeted solutions for real built world environments.