How can CT scanners help manufacturers detect product defects without disassembly?

Written by:

Emily Smith

As a precision engineer, you understand the importance of quality control and ensuring that your products meet the highest standards of performance, safety, and reliability. Detecting product defects is an essential part of the quality control process, and using traditional inspection methods to do this can be time-consuming, costly, unreliable, and sometimes even damaging to the parts.

The quest for quality has helped push new innovations such as CT scanners which offer a non-destructive, innovative, and highly accurate way to detect product defects without disassembly. They offer several solutions that can improve the overall manufacturing process across many industries.

In this article, we will cover:

industries that benefit from CT scanners

Which industries can benefit from a CT scanner?

  • Aerospace – The aerospace industry has zero tolerance for failure, and because of this requires an extremely high level of product reliability. CT scanning is used in root cause failure analyses to identify what went wrong, whether it’s scanning a battery or a number of components made to make up an aircraft.

  • Automotive – CT scanning is used in the automotive industry to effectively analyse vehicle components such as cast components, engine components, brake components, and many more without the need to take them apart first. Automotive companies require this level of detail in order to maintain a high production rate and provide both quality and quantity to their customers.

  • Medical – Medical devices or components that cannot be seen with the naked eye need to be inspected with precision technology. For example, medical devices like stints for the heart are very fragile and small components can be inspected with a CT scanner.

  • Packaging and plastics – Used to highlight product flaws such as leaks, and focus on development opportunities for product design.

  • Electronics, Engineering, and Energy – Commonly used for failure analysis, component positioning, internal quality inspection and spot product defects without disassembly. 

What solutions and value can a CT scanner provide to manufacturers?

product defects with CT scanner

The cost of quality control within manufacturing is extremely important. The cost implications of not quality controlling your products can result in damaged parts going unnoticed, machine failures, or it can jeopardise the company’s reputation as well as compromise public safety.

Successful and precise quality control allows manufacturers to achieve regulatory compliance and optimise their manufacturing processes for the future. 

CT scanners allow manufacturers to virtually see inside their parts without damage or having to physically alter them in any way. This also prevents any unwanted damage, minimises the number of scrap parts, and adds traceability to manufacturing processes.

This provides new opportunities to manufacturers, giving them the chance to look at parts they may have previously turned away, due to their size and lack of capability their machines have. 

CT scanning opens up new opportunities for engineers, enabling them to measure all critical dimensions, no matter how complex the geometry is. The results of a CT scan can be used to analyse and optimise a product’s design throughout all stages of the product life cycle. 

Future-proof technology

Everybody knows that X-ray technology makes hidden things visible, but using CT scanning technology on your parts opens up completely new possibilities in quality assurance and results in significant added value for manufacturers. 

 Let us explain this to you!

  1. Just one scan can provide full certainty: Allowing you to measure and inspect hidden defects that cannot be detected with more traditional measuring machines.
  2. Thanks to CT scanners, you can virtually see inside your parts.
  3. No more complex fixturing. This saves time and money!
  4. Parts can be reproduced after a scan of all internal and external structures even if no CAD model is available. 

Key features of Easy Tom CT scanner

  • Extremely high resolution – Outstanding CT resolution down to 0.4um
  • Flexible solutions – Wide range of applications, easy to use and maintain, small footprint, and easy integration
  • Automatic object positioning – High-grade manipulations
  • One scan provides multiple inspections – Material analysis, geometry, and metrology
  • Lasting investment – Upgradable solutions, reliable, and proven CT equipment
  • Powerful and advanced software – Multiple scanning strategies

Cost vs benefit analysis of CT scanners

Testing has always been a crucial step in the management of quality, and damaging large and expensive components when trying to inspect them no longer makes economic sense for in-demand manufacturers.

When it comes to justifying the cost of a CT scanner, here are several areas in which it can add value… 

  1. Improved Product Quality: A CT scanner can help engineers and manufacturers identify defects and other issues that may not be visible with traditional testing methods. By catching these issues early, they can be corrected before they become larger problems, which can ultimately improve product quality and reduce scrap rates.

  1. Time Savings: With a CT scanner, engineers and manufacturers can quickly and easily perform detailed inspections and measurements of internal structures, reducing the time required for testing and inspection. This can help to speed up the manufacturing process and reduce setup time between each scan.

  1. Cost Savings: By catching defects early and reducing scrap rates, a CT scanner can help to save money on materials and manufacturing costs. Additionally, the time savings from using a CT scanner can help to reduce labour costs and increase productivity.

  1. Competitive Advantage: Having access to a CT scanner can give engineers and manufacturers a competitive advantage in the marketplace. By using this advanced technology, they can improve product quality and efficiency, which can help to attract new customers and retain existing ones.

  1. Regulatory Compliance: In some industries, such as aerospace and medical device manufacturing, regulatory compliance is a critical concern. A CT scanner can help manufacturers to comply with regulations and standards by providing accurate and reliable testing and measurement data.

Want to find out more about CT Scanners?

Join us at our exclusive event where we’ll be demonstrating the most compact and powerful CT scanner yet, the Easy Tom CT Scanner highlighting its advanced capabilities and how they could assist your processes.

Or speak to a metrology expert today

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We’ll give you expert advice on the right precision systems for your application, software to streamline your quality process from drawing to report, plus we’ll support you with sub-contract measurement and calibration services.

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In this article, we will cover:

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