Why Aerospace Manufacturers Rely on 3D Scanning for Inspection and Reverse Engineering

Measuring deviations from design intent, checking fit alignment, or validating aerospace components for compliance all require accurate inspection. 3D scanning for aerospace parts is the most accurate method for OEMs and Tier 1 suppliers to gain real insight into designs and performance. Beyond inspection, 3D scanning creates digital models for reverse engineering, legacy part support, and additive manufacturing integration. This article presents persuasive arguments for high-precision, 3D scanning on aerospace parts. 

What is 3D Scanning in Aerospace?

At its core, 3D scanning is non-destructive, fast, and repeatable imaging. There are different types of 3D scanning that go beyond what conventional methods have been able to achieve.

Blue Light Scanning

Blue light scanning for aerospace components uses an LED light source and lenses to digitally capture complex shapes or curves, like those found in turbine blades. It is line-of-sight scanning, captures millions of points per scan, and is used for surface inspection or digital twin reconstruction. This technology can be helpful to document wear over time or create legacy parts where designs may no longer be available. Interchangeable lenses enable precise measurement of small to medium-sized components with consistently high accuracy.

Industrial CT Scanning

Industrial CT scanning for aerospace parts is a non-contact, X-ray-based technology for internal and external structural analysis. When paired with metrology-grade interrogation software, it is a powerful visualization and analytical tool offering micron-level accuracy. As additive manufacturing takes hold in the aerospace industry, industrial CT scanning is a perfect match to validate processes and make improvements. At Nel PreTech Corporation, we use industry-leading hardware that can scan small parts and parts up to 615 mm in diameter and 800 mm in height. The Zeiss Metrotom industrial computed tomography systems we use are designed to measure and inspect complete components made from plastic, light metals, copper, or even steel. Aerospace components often contain fine microstructures suitable for this type of precision imaging as well.

Use Case: Inspecting 3D Printed Rocket Components with 3D Scanning

A key player in the additive manufacturing of aerospace rocket propulsion systems used Nel PreTech’s CT-based, 3D scanning services to identify flaws in the cooling channels of their rocket thrusters. Being able to visualize the sub-surface voids allowed them to identify a problem early on and adjust printing parameters before catastrophic failure. Read the full case study here. 

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Applications Across the Life Cycle

• Design validation
• First article inspection
• Reverse engineering legacy parts
• 3D printing/additive manufacturing (Fused Deposition Modeling & Powder Bed Fusion) process improvement
• Porosity/void analysis
• Metrology

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Benefits for Aerospace Teams

By delivering high-resolution dimensional data and enabling comprehensive part-to-CAD comparisons, 3D scanning supports aerospace teams in streamlining validation, reducing nonconformities, and maintaining compliance with rigorous industry standards. Here are additional benefits for aerospace designers, researchers, manufacturers, and printers:

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• Faster issue resolution with accurate data, shareable across teams
• Reduced downtime 
• Fewer iterations and prototypes
• Safer, certifiable parts
• Less waste

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How Nel PreTech Corporation Supports the Aerospace Sector

Nel PreTech Corporation uses advanced 3D scanning technology like the ATOS Q blue light scanner and industry-trusted Zeiss CT scanners to deliver fast, reliable data. We pride ourselves on a quick turnaround time with options to expedite as needed. Our process is accredited to ISO/IEC 17025 by A2LA, ensuring an extra layer of confidence and protection. 

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Ready to bring aerospace-grade accuracy to your inspection process? Get a free quote or speak with our 3D scanning experts today.

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