Manual Hole Inspection. Now Automated.

One Device. Millions in Savings.

Aeroscan delivers up to 260,000 objective data points per scan, in seconds, from a single handheld device — replacing hours of manual work with instant, defensible hole quality data your program can rely on.
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Precision in Your Hand

A 1.7kg handheld device that scans holes from 4.75mm to 30mm across aluminum, CFRP, titanium, and steel. Non-contact radial laser illumination generates a complete 3D point cloud in seconds — ±5µm diameter accuracy, ±2µm repeatability, 260,000 data points per scan. No contact. No subjectivity. No delays.

260,000

Data Points Per Scan

Aeroscan's patented radial laser illumination generates a high-density 3D point cloud capturing full hole geometry — including diameter, countersink depth, angularity, grip length, and surface roughness — across a 350° scan with 1° point spacing and 50µm Z-spacing.

±5μm

Diameter Accuracy

LNE-certified measurement accuracy of ±5µm on diameter and ±10µm on countersink depth, with ±2µm repeatability. Validated across aluminum, CFRP, titanium, and steel in mixed material stacks up to 1.75" thick — across every hole size in the 4.75mm to 30mm range.

<15 s

Real-Time Analytics

Data capture is non-contact and nearly instantaneous. The complete point cloud is processed in real time — delivering diameter measurements, defect flags, surface roughness projections, and drill life assessment without removing the part or interrupting production.

One Device. Every Configuration.

Scales to Your Operation

Aeroscan's modular design scales from handheld spot inspection to fully automated assembly line integration — the same sensor, the same data standard, in any configuration. The technology can be readily incorporated into existing robotic and manufacturing systems, and the software integrates directly into your manufacturing execution system. Every scan automatically generates a complete digital record — flagging surface anomalies, measuring countersink geometry, tracking drill bit degradation, reducing gapped fasteners, and eliminating the need for material destacking after drilling. No manual interpretation. No operator subjectivity. High-density, defensible quality data your program can act on immediately and trace through the full service life.

What Every Scan Delivers

01

Go / No-Go Trend Analysis
Continuous SPC with UCL/LCL monitoring. Catch drill wear and process drift before defects occur.

02

Automated Defect Detection
Helical gouges, chatter marks, and anomalies auto-flagged with heat-mapped visualization.

03

Borehole Fingerprinting
Unique surface roughness signature per hole — forensic traceability through the full service life.

04

Drill Life Assessment
Monitor cutting tool degradation over time. Optimize replacement to eliminate preventable rework.

05

Scalable Form Factor
Handheld spot-inspection or automated assembly line — same sensor, same data, same standard.

06

Digital Twin Integration
Every scan feeds a complete digital record — objective, timestamped hole data ready for MES and quality systems.

Aeroscan

An innovative robotic sensor and data acquisition platform that enables next-generation Digital Twin and automated manufacturing — capturing 260,000 objective data points per hole in a single pass.

Radial Illumination
Laser Reflection Captured
Image Processing
Data
Final

LNE-Certified Precision

Aeroscan is the only 3D precision hole measurement solution certified by the French National Metrology Laboratory (LNE) — validated across aluminum, CFRP, titanium, and steel regardless of industry or application.

↓ Measurement Capabilities

Max Stack Thickness: 1.75" (44.5mm)
Hole & Countersink Diameter: 4.75–30.0mm
Material Compatibility: Aluminum, CFRP, Titanium, Steel

↓ Accuracy Capabilities

Diameter: ±0.0002" (±5µm)
Countersink Depth: ±0.0004" (±10µm)
Stack Thickness: ±0.005" (±125µm)
Repeatability: ±0.0001" (±2µm)

↓ Point Cloud

Data Points Per Scan: 260,000
Z-Spacing: 0.002" (50µm)
XY Spacing: 350° at 1° point spacing
Rescan Capability: Full 360°

The Future of Hole Inspection

One-Up Assembly Drill. Measure. Fill.

Aeroscan integrates as an end effector on automated drilling and robotic platforms, enabling single-pass drill, measure, and fill operations.

The legacy process required stopping the line after every hole to measure manually before filling. Every interruption cost time, introduced variability, and produced one or two subjective data points. Aeroscan eliminates that sequence entirely.
The result is a continuous automated workflow capturing 260,000 data points per hole in real time. The line keeps moving. Quality data is generated automatically. Every measurement is traceable from the moment the hole is drilled.
Fewer stoppages mean higher throughput. Automated measurement means fewer rework events. A complete digital record from day one.

METHOD COMPARISON

Manual vs Aeroscan

Traditional hole inspection captures 1–2 measurements per hole — enough to pass or fail, not enough to understand. Aeroscan generates 260,000 data points per hole in under 15 seconds, giving quality and production teams the full picture for the first time.

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Product

MANUAL

AEROSCAN

Inline Inspection Method

Manual gauge, operator dependent

Automated 3D scanning, every hole

Line Stoppage

Required for every hole

None

Accuracy

Variable ±25–50 microns typical

±5 microns

Measurement Variability

High, subjective, operator to operator

Eliminated, objective data every scan

Data Points Per Hole

1–2 manual measurements

260,000 Objective data points

Operator Subjectivity

Significant factor in every inspection

Zero

Consistency

Variable

Identical standard, every hole, every time

Labor Reduction Cost

None

Significant Savings

Drill Life Assessment

None

Immediate data

PREDICTIVE ANALYTICS

Drill Life Assessment

Traditional drill bit replacement is based on assumption. Aeroscan replaces assumption with data. By analyzing each scanned hole for aberrations, wear profiles, and burr formation, Aeroscan detects the first measurable deviation from tolerance before it becomes a defect. Drill bits are replaced based on actual performance, not fixed-interval estimates.

01

First Deviation Detection
Wear, aberrations, and burr formation identified at the earliest measurable point, before any defect occurs.

02

Data-Driven Replacement
Replace drill bits based on actual performance data, not fixed-interval estimates.

03

Full Traceability
Complete performance history of every drill bit from first hole to retirement.
Every additional hole extracted from a drill bit across a multi-year production program represents compounding savings in tooling, labor, and line time. All quantifiable and traceable with Aeroscan data.

Same Sensor. Same Standard. Any Scale.

Aeroscan's design scales from handheld spot inspection to fully automated assembly line integration. The same sensor, the same data standard, in any configuration. The technology integrates readily into existing robotic and manufacturing systems, and the software connects directly into your manufacturing execution system.

Every scan automatically generates a complete digital record, flagging surface anomalies, measuring countersink geometry, tracking drill bit degradation, reducing gapped fasteners, and eliminating the need for material destacking after drilling. No manual interpretation. No operator subjectivity. High-density, defensible quality data your program can act on immediately and trace through the full service life.

Built for Your Production Line

Aeroscan deploys across every stage of production, from initial assembly through MRO. The cost impact is measurable at every level. Fewer line stoppages mean higher throughput. Automated measurement eliminates the rework cycles that drive the highest cost overruns in airframe production. Extended drill bit life through predictive analytics reduces tooling spend across multi-year programs. And a complete digital record from day one eliminates the retroactive data collection that compounds cost as programs mature.

Programs that deploy Aeroscan early don't just improve quality. They build a cost structure that compounds in their favor for the life of the airframe.

Built for the Most Demanding Industries

More production time. Exponentially more data. Millions in savings.

Aerospace

Fastener hole quality is flight-critical. Aeroscan eliminates manual spot checks across airframe production — reducing inspection labor hours by up to 80% while generating objective, auditable data for every hole drilled.

Defense

High-consequence programs demand zero-defect standards. Aeroscan delivers 150,000 data points per hole scan, automated defect flagging, and full traceability — keeping production lines moving without sacrificing compliance.

Shipbuilding

Hull and structural assembly require thousands of precision fastener holes across massive material stacks. Aeroscan scales from handheld spot inspection to automated line integration — same data standard, every hole, every station.

Automotive

High-volume production leaves no room for inspection bottlenecks. Aeroscan replaces slow manual gauging with non-contact 3D scanning that feeds directly into SPC systems — catching process drift before it becomes a production stoppage.

Oil & Gas

Downhole and pressure-critical components demand dimensional accuracy and full traceability. Aeroscan delivers certified 3D hole data across mixed material stacks — reducing rework risk and strengthening quality records.

Power & Turbines

Precision hole geometry directly affects turbine performance and service life. Aeroscan captures complete hole geometry in seconds — enabling proactive drill life management and eliminating costly post-machining defects.