Aerospace Precision Redefined: GKN Aerospace Elevates Quality Control with Creaform 3D Scanning Solutions

The aerospace industry stands as a pinnacle of engineering and safety, operating under some of the most rigorous quality standards globally. The manufacturing and maintenance of aircraft and rocket components demand absolute precision, where even the slightest deviation can have catastrophic consequences. Consequently, every part undergoes continuous, meticulous inspections – not only during production and before deployment but also throughout its operational lifecycle. In this high-stakes environment, precision is non-negotiable, yet speed is equally vital. Protracted inspection processes lead to costly downtime, directly impacting operational efficiency and project timelines. Traditional testing methods often fall short in meeting these dual demands, lacking the necessary speed, comprehensive accuracy, and adaptability required for today’s increasingly complex and intricately designed aerospace components.

This critical challenge was precisely what GKN Aerospace Deutschland GmbH, a prominent global supplier of essential aerospace components including airframe structures, engine parts, and landing gear, was facing. Committed to pushing the boundaries of aerospace innovation and safety, GKN Aerospace recognized the need for a more advanced, efficient, and robust quality control system. Their quest led them to Creaform’s cutting-edge 3D scanning solutions, which ultimately provided the technological leap required to overcome these formidable hurdles and set new benchmarks in aerospace metrology.

At GKN Aerospace, ensuring peak performance, optimal efficiency, and paramount aircraft safety are core priorities. Achieving these objectives necessitates a regime of rigorous and consistent part inspections throughout the entire product lifecycle. By acquiring detailed and accurate data on both manufacturing equipment and finished components, GKN Aerospace empowers its teams to make highly informed decisions. This allows for the swift implementation of corrective actions, proactive problem-solving, and continuous process improvement, all of which are crucial for maintaining its leadership position in the aerospace sector.

However, the company’s existing metrology tools, primarily traditional touch probing systems, presented significant limitations. While offering some level of accuracy for discrete points, these systems were inherently unable to capture sufficient data for truly comprehensive analysis. They provided only selective insights, often missing critical details on complex surface geometries. Moreover, the landscape of aerospace manufacturing was rapidly evolving, with part geometries becoming increasingly intricate and customer expectations for precision and rapid turnaround times escalating. This confluence of internal limitations and external pressures highlighted an urgent need for a new, state-of-the-art measurement solution – one that could provide dense, accurate data quickly and adapt to diverse component types. GKN found precisely what it needed in Creaform’s advanced 3D scanning technology.

Andreas Herkner, Site Quality Manager at GKN Aerospace, articulated the company’s specific requirements: “We were actively searching for a metrology solution that not only offered an exceptionally high degree of accuracy but could also deliver a vast amount of data in a very short timeframe, irrespective of the part’s size or complexity. Furthermore, it was essential for the solution to be mobile, allowing for quick deployment across different manufacturing areas, and immediately ready for use. Seamless compatibility with our existing in-house software systems was also a key criterion, and ideally, we wanted the solution to retain touch-probing capabilities for specific measurement tasks.” These stringent demands underscored the need for a versatile, powerful, and integrated metrology system.

GKN Aerospace Chooses Creaform 3D Scanning Solutions for Unmatched Metrology

After a thorough evaluation, GKN Aerospace discovered that Creaform’s cutting-edge scanning solutions perfectly aligned with its rigorous requirements. Creaform, headquartered in Lévis, Canada, has established itself as a global pioneer in the development and manufacturing of reliable, portable 3D scanners and innovative software. Their renowned Scan-to-CAD solutions are particularly lauded for enabling a truly seamless digital workflow from physical object to digital model. Ultimately, GKN Aerospace made the strategic decision to invest in the MetraSCAN 3D optical CMM scanner and complement it with the sophisticated Creaform Metrology Suite™ software.

The MetraSCAN 3D is a powerful optical CMM scanner designed for precision measurement in demanding industrial environments. It boasts an impressive resolution of 0.025 mm, allowing it to capture even the finest details with exceptional accuracy. Furthermore, its ability to capture data at an astounding rate of 1.8 million points per second translates into unparalleled speed, making it possible to rapidly scan even very large and complex aerospace parts that would take significantly longer with traditional methods. Weighing a mere 1.49 kg, the device is remarkably portable and ergonomically designed, making it extremely user-friendly and highly adaptable to a wide range of applications, from the factory floor to specialized inspection areas. This combination of speed, precision, and portability was a game-changer for GKN Aerospace. “The implementation of the MetraSCAN 3D into our existing infrastructure was remarkably seamless,” noted Andreas Herkner. “Our metrology team was able to integrate the system into our established workflows almost immediately, requiring only minimal training, which further accelerated our adoption and return on investment.” This ease of integration highlights Creaform’s commitment to user-centric design and robust software compatibility.

Achieving Faster and Smarter Inspections with Digital Precision

With the integration of Creaform’s advanced 3D scanning solutions, GKN Aerospace has fundamentally transformed its quality control processes. The company is now able to quickly capture high-quality, dense 3D data of its components and manufacturing equipment. This rich dataset is then directly compared against original 3D CAD models, facilitating frequent and comprehensive inspections. This capability allows GKN Aerospace to identify even the most subtle deviations, manufacturing imperfections, or quality issues with unprecedented speed and accuracy. The rapid identification of anomalies means that corrective actions can be initiated and implemented swiftly, minimizing costly rework, reducing scrap rates, and preventing potential delays in production schedules. Crucially, this agility enables GKN Aerospace to respond to evolving customer requirements and stringent aerospace industry standards faster and more effectively than ever before.

The MetraSCAN 3D plays an absolutely vital role in ensuring the inherent safety and long-term reliability of aerospace components. Its high precision and comprehensive data capture are particularly beneficial for parts subjected to extreme operational stresses, such as those found in engine components or structural elements. By providing a complete digital twin of the physical part, engineers can perform in-depth analysis of surface integrity, geometric accuracy, and potential stress points, contributing directly to safer and more robust aircraft and spacecraft. The ability to monitor these critical parts throughout their lifecycle with consistent, high-fidelity data adds another layer of security and confidence.

Andreas Herkner is unequivocally convinced of the substantial value and return on investment derived from this strategic acquisition. “Thanks to Creaform’s MetraSCAN 3D, we have successfully achieved a completely new level of quality control across our operations. The combination of accuracy, impressive speed, and user-friendliness inherent in this technology has enabled us to perform far more detailed and comprehensive evaluations than ever before, allowing us to respond swiftly and effectively to any identified issues,” he stated with confidence. He further elaborated, “This significant investment has not only dramatically improved our operational efficiency by streamlining inspection processes but has also profoundly strengthened our unwavering commitment to delivering the absolute highest quality aerospace components to our global clientele. We are extremely satisfied with the tangible results and the strategic advantage this partnership has provided.”

Through this successful implementation, GKN Aerospace has found a robust and reliable partner in Creaform and its innovative product offerings. Creaform’s understanding that the needs of aerospace stakeholders can vary greatly, from large-scale manufacturers to specialized repair facilities, drives its commitment to providing a comprehensive and adaptable portfolio of solutions precisely tailored to the sector’s unique challenges. This strategic alignment ensures that GKN Aerospace, and indeed the broader aerospace industry, can continue to push the boundaries of innovation and safety through advanced metrology. To delve deeper into Creaform’s extensive range of aerospace solutions and discover how they are shaping the future of precision manufacturing, explore their dedicated resources HERE.

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*All Photo Credits: Creaform