Aerospace Manufacturing - Embracing Safety, Elevating Performance, and Achieving Sustainability Goals

In the aerospace industry, precision is not a luxury; it's a necessity. Critical engine components like turbine blades and blisks are subject to stringent quality requirements. Traditionally, inspection and measurement have been time-consuming and costly, accounting for 20% of total production costs and 25% of production time. However, the industry is on the cusp of a transformative change, where speed and accuracy are no longer mutually exclusive.

The Challenge of Speed vs. Accuracy

The aerospace sector has long struggled to maintain accuracy while increasing production speed. Inspecting high-precision parts is a meticulous process, and any compromise on quality can lead to catastrophic results. But what if aerospace manufacturers could have the best of both worlds?

Innovations in Metrology and Inspection

Recent advancements in metrology and inspection technologies are revolutionizing how aerospace components are measured and inspected. For instance, automated metrology solutions integrate robotics into inspection workflows to enhance efficiency. These systems may rotate parts for better access or employ automated batch-processing systems (BPS) that use robotics to load and unload parts for measuring with coordinate-measuring machines (CMMs) or optical 3D scanners.

Advanced CMM Technology

Next-generation CMMs are another leap forward, with some aerospace manufacturers reporting a 74% reduction in the time taken for standard turbine blade measurement programs. These CMMs can deliver accurate and reproducible results in as little as 70 seconds, allowing for measuring more parts in less time.

Automated Optical 3D Scanning

Using automated optical 3D scanners allows for the rapid capture of 3D measurement data, enabling efficient measurement programs with high repeatability. This automation speeds up the inspection process and frees operators to manage multiple machines or analyze data, further accelerating production.

AI-Enhanced Microscopy

Artificial intelligence (AI) is also making significant strides in increasing inspection speed. In X-ray microscopy, for example, AI accelerates data acquisition and interpretation, reducing what could be a 24-hour high-resolution scan to a much shorter duration. AI also improves accuracy in image segmentation for materials like composites and advanced coatings, which are increasingly used in aerospace.

Technical Cleanliness and Particle Inspection

Innovations are not limited to dimensional measurements. Intelligent software and motorized microscopy have sped up the inspection of technical cleanliness and particle analysis, automating the sizing of particles to determine quickly whether a part meets cleanliness specifications.

Nondestructive Measuring Techniques

Metrology-grade CT scanning is a game-changer for nondestructive measurement. It saves time by eliminating the need to cross-section components and improving dimensional accuracy. This technology allows for inspecting critical internal dimensions without damaging the component, enhancing production speed and sustainability.

MRO Advancements

In maintenance and repair operations (MRO), optical 3D scanners can quickly digitize components to identify defects or failures. Intelligent inspection software then analyzes the surface defects, enabling faster problem identification and corrective actions.

Conclusion

The aerospace industry is achieving a new efficiency level with advanced metrology and inspection technologies. Automation, robotics, AI, and next-generation measurement techniques enable manufacturers to meet high standards while meeting production demands. These innovations are not just about speed; they're about delivering precision at pace, reducing production time, and ensuring the safety and reliability of critical aerospace components. With these tools, the industry is poised to soar to new heights of productivity and excellence.