Can you CT scan a metal part and generate a CAD model that captures complex internal geometry?

Yes, as always, there are limitations based on part density and path lengths.

Can you detect microscale pores, cracks, or voids in metal samples and provide 3D defect analysis?

Yes, but it depends on the size of the pore, crack, or void and on the size of the sample. This affects the scanning resolution.

Can your micro-CT detect density-differential features such as air bubbles or voids within a fluid-impregnated part?

Yes, it can, as long as the part, fluid, gas mixture has a density difference of 10-15%.

Can you CT scan thick-walled injection-molded parts with embedded metal inserts (e.g., copper, brass) and detect gaps as small as 0.1 mm?

Completing measurements on multi-material parts is possible, and actually having more of the low-density material helps in the scanning process.

Can you CT scan an ultrasonically-welded sealed device without physically opening or cutting it?

Yes, that is one of the greatest benefits of CT. It is almost always non-destructive. The only cases are when the area of interest requires an extremely high resolution or the object does not fit into the machine due to its height.

Can you use CT to compare a known-good part against a potentially defective one to identify the root cause?

Without a doubt. This is one of our most common analysis types, called colormaps (or heatmaps), where we can compare an object to a CAD model or to other samples.

Can you scan an additive-manufactured (3D-printed) part in-process or post-build to validate internal quality and porosity?

Certainly, there are limits to the amount of high-density material we can scan, but porosity and inclusion analysis on additive manufacturing is something we are quite versed in.

What is the maximum part size your CT scanner can accommodate?

Approximately 30 inches tall x 24 inches wide, or roughly 800 mm by 615 mm.

What is the minimum feature size or resolution your CT system can reliably detect?

The smallest feature size range we can reliably detect between our 2 machines is 15-21 micrometres, which is 3x our smallest voxel size.

Does radiation from the CT scan risk corrupting or erasing data stored on electronic components (EEPROM, flash memory) inside an assembly?

There is a small risk when scanning memory devices because CT scanners use ionizing X-ray radiation. The level of risk increases with longer scan times and higher X-ray power settings. However, studies have shown that the exposure required to cause significant, unrecoverable damage is substantially greater than the scan durations and settings typically used by NPC.

Industrial CT Scanning Services | Industrial Computed Tomography

Complex Geometry Demands More Than Surface Inspection

Traditional metrology tools struggle when additive manufacturing introduces:

Internal cooling channels
Lattice structures
Organic geometries
Thin walls
Hidden porosity
Support removal challenges
Multi-material assemblies
Internal defects inaccessible to tactile probing

Industrial CT scanning provides full volumetric inspection of the entire part, allowing engineers to evaluate internal and external geometry simultaneously.

COMMON CHALLENGES SOLVED

Internal porosity analysis
Powder entrapment detection
Dimensional verification
CAD-to-part comparison
Wall thickness analysis
Crack & void identification
Reverse engineering
Assembly validation
Print process optimization
Failure analysis

Inspection Technologies Built for Additive Manufacturing

INDUSTRIAL CT SCANNING

Non-destructive volumetric inspection for internal and external evaluation.

Capabilities include:

Internal geometry verification
Porosity analysis
Void detection
Wall thickness analysis
STL generation
CAD comparison
Assembly verification
Failure analysis

Learn More About CT Scanning Services:
Industrial CT Scanning Services

Additive Manufacturing Applications We Support

Aerospace

Inspect lightweight structures, internal channels, manifolds, and flight-critical geometries.

Medical Devices

Validate geometry, porous structures, and intricate internal pathways.

Automotive

Analyze EV components, lightweighting strategies, and production repeatability.

Tooling & Rapid Prototyping

Accelerate development with rapid inspection and reverse engineering support.

Defense

Verify mission-critical components with non-destructive internal analysis.

CT scan showing damage of electronic device

Research & Development

Support material studies, design iteration, and manufacturing optimization.

Faster Answers. Better Data. Lower Risk.

SEE INTERNAL FEATURES WITHOUT DESTRUCTION	Evaluate hidden geometry without sectioning or damaging parts.
REDUCE DEVELOPMENT CYCLES	Identify defects and dimensional deviations earlier in the process.
VALIDATE COMPLEX DESIGNS	Inspect geometries inaccessible to conventional measurement methods.
IMPROVE MANUFACTURING CONFIDENCE	Use accurate inspection data to support production decisions.
SUPPORT DIGITAL WORKFLOWS	Generate datasets compatible with CAD comparison and digital twin strategies.
ACCESS ENGINEERING SUPPORT	Collaborate directly with experienced engineers, physicists, and metrology experts.

Why CT Scanning Is Critical for Additive Manufacturing

Featured Content:

Why CT Scanning Is the Only Reliable Way to Inspect Complex Additive Manufacturing Geometries

Additive manufacturing continues pushing design freedom forward, but inspection methods must evolve alongside it. Industrial CT scanning provides a complete volumetric dataset capable of validating internal geometry, detecting porosity, and revealing defects that surface-only inspection methods cannot identify.

Relevant Content

Accredited Inspection Backed by Engineering Expertise

Nel PreTech Corporation is an ISO 17025 accredited laboratory with more than 30 years of problem solving under our belts. We’ve served 3,000+ clients with fast turnaround times, engineering-focused support, and advanced CT & metrology systems.

OUR PEOPLE

Engineers
Physicists
Metrology specialists
CT experts

Complex additive manufacturing projects require more than software and equipment alone. Accurate results depend on inspection strategy, scan setup, reconstruction quality, and experienced analysis.

FAQ

What inspection methods are best for additive manufacturing parts?

Additive manufacturing parts often require advanced inspection methods because many critical features are internal or inaccessible to traditional measurement tools. Industrial CT scanning is one of the most effective inspection technologies for additive manufacturing because it captures complete volumetric data of both internal and external geometry without destroying the part.

Additional inspection methods may include:

Blue light 3D scanning
Coordinate Measuring Machine (CMM) inspection
Video measurement systems (VMM)
Laser scanning
Dimensional metrology

The best method depends on the part geometry, material, tolerance requirements, and inspection objectives.

Can CT scanning inspect internal features in 3D printed parts?

Yes. Industrial CT scanning is specifically suited for evaluating internal features inside additive manufacturing components. CT scanning can inspect:

Internal cooling channels
Lattice structures
Hidden voids
Porosity
Cracks
Powder entrapment
Assembly integrity
Wall thickness

Unlike conventional inspection methods, CT scanning allows engineers to analyze internal geometry without sectioning or damaging the component.

Can CT scanning measure porosity in additive manufacturing parts?

Yes. Industrial CT scanning is one of the most effective methods for porosity analysis in additive manufacturing. CT data can identify:

Void size
Void distribution
Total porosity percentage
Defect location
Connectivity between defects

This information helps engineers optimize print parameters, validate manufacturing consistency, and evaluate part quality.

How accurate is industrial CT scanning for additive manufacturing inspection?

Industrial CT scanning accuracy depends on several factors, including:

Part size
Material density
Scan resolution
Geometry complexity
Required tolerance

Modern industrial CT systems can achieve extremely high-resolution datasets suitable for dimensional metrology, internal defect analysis, and CAD-to-part comparison. Nel PreTech evaluates each project individually to determine achievable resolution and measurement capability.

Can Nel PreTech compare a printed part directly to CAD data?

Yes. Nel PreTech can perform CAD-to-part comparison using CT scanning and 3D scanning technologies. This process allows engineers to:

Compare printed geometry against nominal CAD
Identify dimensional deviations
Generate color deviation maps
Validate critical features
Analyze warpage or distortion

This is commonly used during prototype validation and production process optimization.

Does CT scanning damage additive manufacturing parts?

No. Industrial CT scanning is a non-destructive inspection method. The part remains intact throughout the scanning process, allowing it to be further tested, assembled, or placed into service after inspection. In regards to the ionizing X-ray radiation, studies have shown that the exposure required to cause significant, unrecoverable damage is substantially greater than the scan durations and settings typically used by NPC.

What deliverables can Nel PreTech provide for additive manufacturing inspection?

Deliverables may include:

CT reconstruction datasets
3D STL files
Color deviation maps
Porosity analysis reports
Wall thickness analysis
Dimensional inspection reports
GD&T analysis
First article inspection (FAI) documentation
Cross-sectional imagery
Engineering consultation

Deliverables are tailored to the project requirements and customer objectives.

Can additive manufacturing inspection help improve print quality?

Yes. Inspection data from CT scanning and advanced metrology can help manufacturers:

Optimize print parameters
Reduce scrap
Improve repeatability
Validate process changes
Identify recurring defect patterns
Improve dimensional consistency

Inspection often becomes a critical feedback loop for additive manufacturing process development.

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Industrial CT Scanning & 3D Inspection for Additive Manufacturing

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