Transform Large-Scale Inspection with 3D Laser Scanning

A leading company based in Turkey specializes in manufacturing advanced composite parts and assemblies for sectors such as aerospace, automotive, and industrial manufacturing. With a strong focus on R&D, innovation, and customer satisfaction, it actively pursues new technologies to enhance production quality and operational efficiency.

When tasked with inspecting a large composite flange measuring 2.5 meters in diameter, the company required a more capable, flexible, and precise measurement solution. Limitations in the reach and accuracy of existing tools led them to explore non-contact 3D scanning technologies. The integration of the TrackScan Sharp-S optical 3D scanning system and i-Probe 500 proved transformative—enabling fast, in-house, high-precision inspections while significantly improving efficiency and autonomy.

The Challenge: Accurate Measurement of Large Composite Parts

The company faced a pressing challenge common in composite material production: accurately measuring large and geometrically complex parts while keeping up with production demands. The part in question—a composite flange with a 2.5-meter diameter—was built from high-rigidity, reflective composite material. It required precise verification of hole positions and internal profiles, but the traditional probing tools of the company had a reach limit of just 1.2 meters, making full inspection impossible.

Additionally, the flange was too heavy to move without disrupting production, and its reflective surface made it difficult to scan using conventional optical systems. Accuracy over long distances, scanning efficiency, and ease of deployment were all critical requirements.

Technical Requirements and Performance

The company's inspection needed to meet several stringent requirements:

• Sub-millimeter accuracy across a 2.5-meter part
• Effective measurement over distances of 2–3 meters or more
• Fast scanning time to avoid production delays
• Ability to handle reflective composite surfaces without powder spraying

The Solution: TrackScan Sharp-S & i-Probe 500

To solve these challenges, the company deployed our TrackScan Sharp-S, a portable 3D scanning system with advanced optical tracking, along with the i-Probe 500, a precision probing tool designed for accurate data capture of internal geometries.

The scanning and probing operation was conducted on-site, directly in the production area, minimizing workflow interruptions. The full measurement process—including equipment setup, scanning, probing, and data validation—was completed in under an hour, a massive improvement compared to traditional methods.

TrackScan Sharp-S delivered on all fronts. Its high-speed, high-resolution 3D data acquisition ensured that even subtle deviations in hole positioning or flange curvature could be detected with confidence.

The i-Probe 500 added an extra layer of capability by reaching internal dimensions that were previously inaccessible due to the physical limitations of older equipment.

Key advantages of this solution included:

• Marker-free scanning from distances up to 8.5 meters
• High-accuracy measurement without requiring surface treatment
• Fast, real-time data processing
• Seamless probing of hard-to-reach internal features
• Handled the smooth, reflective composite material without requiring surface coating

Competitive Advantage of Our 3D Solution

In comparison with traditional tools like calipers, measuring tapes, or CMM arms, our integrated solution provided the company with unmatched:

• Flexibility: No need for part relocation or setup changes.
• Speed: Entire process completed within an hour.
• Accuracy: Sub-millimeter precision of up to 0.025 mm, even from long distances.
• Simplicity: Marker-free, surface-friendly scanning reduces labor.

Results and Impact

After adopting Scantech's 3D scanning solution, the company realized significant operational and quality improvements:

• Reduction in inspection time
• Complete in-house inspection workflow
• Reduced dependency on third-party services
• Improved measurement accuracy and data reliability
• Better control over quality assurance
• Minimized production downtime

More importantly, this technology enabled real-time decision-making during production, empowering the company to take immediate corrective actions and ensure that every component met strict dimensional tolerances.

Conclusion

The integration of our high-precision 3D scanning technology has empowered the company to take full control of their quality inspection process. By bringing large-part inspection in-house, the company gained efficiency, reduced operational costs, and improved production quality—all critical to staying competitive in high-performance industries.

For manufacturers working with large composite structures or needing fast, accurate, non-contact metrology solutions, we offer a field-proven path forward.