10 Frequently Asked Questions About Industrial CT Scanning

Industrial computed tomography (CT) scanning is an advanced imaging technology used for precise internal and external inspection of components across industries. Below are some of the most common questions regarding its capabilities, limitations, and applications.

1. What Can Industrial CT Scanning Be Used For?

Industrial CT scanning is used for a variety of applications, including:

• Dimensional inspection – Ensuring components meet precise specifications.
• Porosity analysis – Identifying internal voids and material density variations.
• Failure analysis – Detecting defects, cracks, inclusions, or inconsistencies within parts.
• Reverse engineering – Creating accurate digital models of physical objects.
• Assembly verification – Inspecting how components fit together without disassembly.
• Colormaps and layouts – Providing intuitive, color-coded representations of material variations and defects.
• Wall thickness analysis – Measuring and visualizing thickness variations to detect weak points.
• Capability studies – Evaluating process capability through statistical analysis of scanned components.

2. Where Can Industrial CT Scanning Be Used?

Industrial CT scanning is utilized in aerospace, automotive, medical device manufacturing, electronics, and additive manufacturing industries, among others. It is applicable in both research and quality assurance environments.

3. How Do I Know If My Part Can Be Scanned?

Several factors determine if a part is suitable for CT scanning:

• Material composition – Best suited for plastics, composites, ceramics, and light metals. Denser materials like steel or lead may require higher x-ray energies, and intensities (ie. radiation power).
• Size and geometry – Must fit within the scanner's scan envelope. For example, the Zeiss Metrotom 1500 CT scanner has a cylindrical volume up to 615mm and max height 800mm or up to 330mm diameter X 870mm.
• Complexity – Highly intricate parts with hidden features are appropriate candidates for CT.
• Resolution requirements – Smaller features require higher resolution, which affects scan time and image quality.

4. How Long Does a CT Scan Take?

The duration of a scan depends on:

• Part size – Larger objects take longer to scan.
• Resolution needs – Higher resolutions increase scan time.
• Material density – Denser materials require longer exposure times.
• Number of parts – Batch scanning may extend processing time.

Depending on these factors, typical scan times range from minutes to several hours.

5. Can Multiple Parts Be Scanned at Once?

Yes, multiple parts can be scanned simultaneously if they fit within the scanner's volume. However, resolution and image quality or clarity may vary based on positioning and density differences between parts.

6. What CT Scanning Services Are Available in an Inspection Lab?

When outsourcing CT scanning to an inspection lab, customers can expect services such as:

• Batch scanning or scan optimization to efficiently process multiple components in a single scan.
• Expert defect analysis utilizing AI-driven software for rapid identification of internal flaws.
• Comprehensive dimensional metrology reports to verify product compliance.
• Advanced software tools that assist in artifact reduction, contrast enhancement, and precise defect detection.
• AI-based reconstruction algorithms optimize image clarity and improve feature recognition in challenging materials.
• Data processing and visualization software that converts raw scan data into interactive 3D models for in-depth analysis.

7. What Can You See with CT Scan Data?

CT scans provide highly detailed 3D models and internal views of a part, revealing:

• Internal cavities, cracks, or voids
• Material density variations
• Assembly misalignments
• Precise dimensional measurements
• Foreign material inclusions

8. What Materials Are Best Suited for Industrial CT Scanning?

Ideal materials include:

• Plastics and polymers – High contrast, excellent for defect detection.
• Composites and ceramics – Used for aerospace and medical applications.
• Light metals (aluminum, magnesium, titanium) – Common in automotive and aerospace.
• Organic materials – Applicable for research and biological studies.

Dense metals, such as steel and tungsten, can be scanned but require higher radiation power and longer scan times.

9. Are There Size Limits for CT Scanning?

Yes, parts must fit within the scanner’s volume, which varies by machine. For example:

• Small, high-resolution scans (micron-level details) require compact parts.
• Large parts (over a meter) may need specialized, high-energy scanners.

10. How Does Radiation Power Affect a Scan?

Radiation power influences:

• Penetration depth – Higher power is needed for denser materials.
• Image clarity – Too much power can cause noise or artifacts.
• Scan speed – More power allows faster scanning of thick parts.

Industrial CT scanning is non-destructive and safe, with controlled radiation exposure that does not alter or damage the scanned material.

Final Thoughts on Industrial CT Scanning

Industrial CT scanning is a powerful tool for quality control, failure analysis, and research. While it has some limitations regarding material density and size constraints, its ability to provide detailed internal and external data makes it indispensable across industries. If you have questions about whether CT scanning is right for your application, contact Nel PreTech for expert guidance.

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