Table of Contents
- Key Players in the Aerospace NDT Industry
- Innovations in Aerospace NDT Methods
- The Challenges That Are Inspiring Innovation in Aerospace NDT
- The Aerospace Industry in 2025
- Key Takeaways
- FAQs
- References
Plato’s quote “Our need will be the real creator” has held true for ages. It has even been refined to better suit our comprehension, famously heard in the form of “Necessity is the mother of invention.” Similarly, technology and innovation, especially in the non-destructive testing (NDT) industry are not stagnant phenomena.
The rise of aerospace NDT services and related technology has catalysed because of the effects of the demands of the field. While human flight was once an impossible thought, we have grown to aim for larger payloads and more efficient and complex inspections to ensure their safety. The companies working towards these goals, and researchers studying the minuscule details are the forerunners of this innovation, building the road to the future brick-by-brick.
Key Players in the Aerospace NDT Industry
The NDT for aircraft safety industry forerunners have put in years of perseverance and research to get to that point, with intensive compliance, research, and innovation. A few companies have consistently landed on the top of this list, with aerospace NDT services and products that have greatly benefitted the industry. These include:
- Evident Scientific
- Eddyfi Technologies
- Baker Hughes
- GE Measurement and Control
- Nikon Metrology
- Mistras Group
Source: https://www.mordorintelligence.com/industry-reports/non-destructive-testing-in-aerospace-defense-market/companies
Innovations in Aerospace NDT Methods
With the help of experts, researchers, engineers, scientists, and aerospace NDT companies such as the ones mentioned above, the industry has taken leaps and bounds in terms of technological growth.
NDT methods have been augmented and fused with other technologies, including other NDT methods to better accommodate the needs of this fast-moving and colossal sector. A brief overview of recent innovations in aerospace NDT is as follows:
1. Phased Array UT
Multi-axis robotic crawlers equipped with 128-element linear arrays and adaptive focal laws for CFRP wingbox inspections. These enable simultaneous multi-angle beam steering in a single pass, reducing scan time compared to traditional UT.
Image Credit: NDT.Net
2. Laser Ultrasonic Testing (LUT)
In this technique, q-switched non-contact Nd: YAG lasers generate and detect ultrasonic waves as a result of the thermoelastic effect. Ideal for high-speed composite scans, it also eliminates couplant and surface prep.
Image Credit: TWI Global
3. Pulsed Eddy Current Arrays (PECA)
Multi-frequency excitation with planar spiral coils can deeply penetrate engine turbine blades. This can measure the decay rate of the eddy currents that have been introduced, providing material thickness and corrosion data for the test subject.
Image Credit: Eddyfi
5. AI Signal Analysis
Convolutional neural networks (CNNs) filter noise from ECT signals in aging aircraft. They help reduce false positives in aluminium skin inspections. This is critical for aviation NDT services targeting quick turnaround as they can process thousands of A-scans every second.
6. Terahertz Imaging (THz)
Terahertz waves map dielectric properties in hybrid material bonds like the CFRP-to-titanium in aircraft nacelles. These can resolve adhesive voids and kiss bonds. Limited to non-conductive materials, aerospace NDT companies are developing hybrid THz-UT systems for metallic interfaces.
Image Credit: Springer
7. Digital Twin
Real-time NDT data from various techniques like PAUT and ECT feeds into Digital twin software to simulate defect propagation in NDT aircraft structures. It predicts the remaining useful life (RUL) of parts like wing ribs for condition-based maintenance.
Image Credit: SW Siemens
8. Guided Wave Ultrasonics (GWUT)
GWUT uses low-frequency Lamb waves to inspect longitudinal wing stringers without disassembly. Unrelated to NDT, this NDT technique has also been applied to de-ice aircraft to improve flight safety. (Yibin Wang, 2017)
9. Automated Thermographic Drones
New-age drones deploy active thermography for in-flight damage assessments. The high-resolution data obtained is streamed via 5G to aviation NDT services hubs.
10. Hyperspectral Imaging (HSI)
300-band spectral cameras are used to detect chemical degradation in composite fairings. This technique identifies resin oxidation before visible delamination.
Image Credit: Invision-news
These aerospace NDT advancements address the gaps in speed, accuracy, and accessibility, driven by aviation trends that lean toward lighter materials and net-zero operations. The sector’s trajectory hinges on collaboration between key players in aerospace NDT and OEMs to standardise and scale these tools for global MRO ecosystems.
The Challenges That Are Inspiring Innovation in Aerospace NDT
Challenges and hurdles are what lead to the need to grow and improve. The aerospace industry has challenges of its own that help it grow, despite the accessibility to NDT techniques and advanced equipment. These challenges comprise the following:
1. Composite Material Characteristics
Ultrasonic testing (UT) inefficiency has become a concern in Carbon Fibre-Reinforced Polymer (CFRP) components.
- Conventional UT struggles with anisotropic material properties which require multiple probe angles to capture defects like delamination and porosity.
- This slows inspection speed in curved or layered structures like wing skins. Phased Array Ultrasonic Testing (PAUT) with adaptive focal laws used for inspection with robotic arms (e.g., Evident’s’ FlexoFORM scanners), help reduce scan passes.
Image Credit: Evident Scientific
2. Eddy Current Testing
ECT often shows limited depth resolution in inspecting multi-layered aircraft alloys like in engine turbine blades.
- Conventional eddy current testing (ECT) detects surface cracks but fails to resolve subsurface corrosion or fatigue cracks beneath conductive coatings. The thermal barrier coatings on Rolls-Royce Trent blades are an example of where this technique might fail.
- This increases the risk of in-service failures. Pulsed Eddy Current Array (PECA) systems are a solution, as they combine multi-frequency excitation and AI-driven noise reduction.
3. Emissivity in Thermography
Inconsistent heat emissivity in hybrid material joints (e.g., CFRP-to-titanium fuselage brackets) is a hurdle in Thermography Testing.
- Passive thermography produces false positives due to variable emissivity at material interfaces, complicating bond-line integrity checks. This forces operators to revert to slower tap testing or X-ray.
- Lock-in thermography with modulated heat sources can isolate defect signals from emissivity noise, improving SNR (signal-to-noise ratio).
4. Phased Array UT and Data Overload
High-resolution PAUT generates terabytes of data during full-wing inspections, overwhelming manual analysis, but human review risks overlooking sub-critical flaws like micro-porosities in spar caps.
- This increases downtime during MRO (maintenance, repair and operations). AI-powered defect recognition auto-flags anomalies using convolutional neural networks (CNNs).
5. Accessibility in Confined Areas
Manual NDT is impractical for internal fuel tank inspections as the confined space can be a hazard for human operators. Traditional borescopes also tend to miss corrosion under the foam insulation. For internal fuel tank inspections, workers should wear custom - made safety suits for better protection.
- This increases the risk of fuel leakage and airworthiness violations. Magnetic crawler robots with ECT sensors can successfully navigate tank interiors, while streaming real-time data to aviation NDT services teams.
6. Standardisation Lag in Additive Manufacturing
The lack of standardisation in NDT methods for 3D-printed aerospace components is another hurdle. LPBF (Laser Powder Bed Fusion) parts have unique defect signatures like unmelted powder, residual stress, etc.
- These issues can delay the certification of additive-manufactured parts, hindering adoption in next-gen platforms.
- Micro-CT scanning paired with digital twin helps cross-check and creates benchmark datasets for regulatory acceptance.
Image Credit: SquareSpace
7. Sustainability
Large components such as landing gear forgings require high-energy consumption to be inspected by X-ray radiography inspection.
- Traditional X-ray requires high power consumption, which is incompatible with net-zero aviation goals that aim for zero carbon emissions by 2050.
- Neutron radiography detects hydrogen embrittlement in steel with lower energy use, which is better suited for this scenario.
The sector aligns with aviation trends demanding faster, safer, and greener inspections by addressing granular technical bottlenecks.
The Aerospace Industry in 2025
The obstructions and challenges in inspection processes have been an accelerant to the research and development in aerospace NDT methods. The industry has made big moves to further operations and technology, some of which include:
1. Flyability
Flyability operates an innovation hub in Lausanne, Switzerland, to advance collision-tolerant drones for internal fuel tank inspections. The Elios 3 now features LiDAR mapping and 4K thermography for real-time defect detection.
2. Adaptix
Adaptix is working on a project set to develop a fast-acquisition 3D X-ray inspection system that is robot-mounted. It uses its Digital Tomosynthesis technology to inspect larger aerospace components made of composites.
3. GE Measurement
GE’s new Munich facility produces inspection robots equipped with various sensors for confined space inspections. Their Sensiworm robot, resembling an inchworm is also taking the industry by storm with its NDT abilities.
Image Credit: Aviation Week
4. Mistras Group
Mistras provides inspection data management software along with conducting intense research and development of NDT techniques. Their softwares help create tamper-proof logs for NDT aircraft safety, helping companies reduce audit time as well as ensure compliance with the strict industry regulations.
These aviation and aerospace industry inspection trends merely touch the tip of the iceberg of the big moves in this industry. However, given the high demand in the sector, it is certain that the future of NDT in aerospace is bright and set to grow exponentially.
Key Takeaways
- Leaders like Evident, Eddyfi, and Baker Hughes are resolving challenges in composite inspections, data overload, and additive manufacturing through R&D investments and collaborations with OEMs.
- Innovations such as AI-assisted ECT, terahertz bond-line imaging, and autonomous thermographic drones address speed, accuracy, and sustainability gaps.
- LiDAR-equipped drones, Low-energy CT scanners, and blockchain-certified NDT data align with net-zero goals and stricter aviation regulations.
FAQs
1. How do digital twins enhance aircraft safety?
Ans: By integrating real-time PAUT or ECT data, digital twins simulate defect growth in components, predicting remaining lifespan with accuracy.
2. How are aerospace NDT companies aligning innovations with net-zero aviation goals?
Ans: NDT service providers deploy various methods like low-energy X-ray CT systems for additive manufacturing inspections, while some use blockchain-certified inspections to reduce audit energy waste, supporting IEA’s 2050 net-zero targets.
References
1. Aviation. (n.d.). Retrieved from IEA
2. Bjerregaard, L. (n.d.). GE Develops Worm-Inspired Robot For On-Wing Engine Inspections. Retrieved from Aviation Week
3. Cranfield University. (n.d.). ATI robot-mounted 3D X-ray inspection project. Retrieved from Cranfield University
4. GE. (n.d.). GE Oil & Gas to use robotics and 3D printing in futuristic Talamona plant. Retrieved from GE
5. Mistras. (n.d.). Inspection Data Management Services & Software. Retrieved from Mistras
6. NDT In The Aerospace And Defense Top Companies Source. Retrieved from Mordor Intelligence
7. NDT Testing Struggles to Incorporate New Technologies. (2018). Retrieved from Aviation Maintenance
8. Towsyfyan, H. e. (2020). Successes and challenges in non-destructive testing of aircraft composite structure. Chinese Journal of Aeronautics, 771-791.
9. University, C. (n.d.). improved performance of Rolls-Royce aero-engines.
10. Wang, Z.-M. e. (2025). "Dual-Vehicle Heterogeneous Collaborative Scheme with Image-Aided Inertial Navigation.". Aerospace, 39.
11. Yibin Wang, e. a. (2017). Progress on ultrasonic guided waves de-icing techniques in improving aviation energy efficiency. Renewable and Sustainable Energy Reviews, 638-645.
