Industrial CT Scanning
Also known as: X-ray CT, Computed Tomography, Industrial CT, Porosity Analysis, Internal Inspection
Industrial computed tomography rotates a part in an X-ray beam and reconstructs a full 3D voxel volume of its interior. It is the only non-destructive method that reveals internal porosity, lack-of-fusion defects, cracks, inclusions, and the geometry of internal channels — none of which are visible from the outside. Analysis software (Volume Graphics VGSTUDIO, others) quantifies pore size/distribution, measures internal dimensions, and compares the scanned geometry to the nominal CAD (nominal/actual deviation).
Why AM parts need this
AM is uniquely prone to internal defects — gas porosity, lack-of-fusion voids, keyhole pores, and trapped powder in internal channels — that conventional surface inspection cannot detect. For aerospace, medical, and fatigue-critical AM parts, CT is the accepted method to qualify internal integrity and verify that internal channels are clear of powder after depowdering. CT also verifies that conformal cooling channels and lattices match the design intent. Porosity quantified by CT feeds directly into fatigue-life and HIP decisions: high internal porosity flags a part for HIP or rejection.
Key parameters
Finer voxel = smaller detectable defect, but smaller scannable part. Sub-10 µm for small dense parts; 50–150 µm for large components.
Smallest reliably detected pore is roughly 2–3 voxels across. To find 20 µm pores, need ~7–10 µm voxel.
X-ray penetration limits part size/density. High-energy (450 kV / linac) systems penetrate dense titanium and steel; aluminium penetrates much further.
Depends on resolution, part size, and number of projections. Production CT cells automate handling for serial inspection.
Compatible AM processes
Compatible materials
Limitations
- X-ray penetration limits part size and density — thick dense titanium/steel sections may exceed system capability
- Resolution trades against part size — you cannot get fine voxel resolution on a large part in one scan
- Capital-intensive and slower than surface metrology — typically a sampling or qualification tool, not 100% inline (except in automated production CT cells)
- Beam-hardening and scatter artefacts require careful setup and calibration for quantitative porosity measurement
- Detects defects but does not fix them — feeds HIP / accept-reject decisions
Related tools
Providers
ZEISS Industrial Metrology
German precision-optics and metrology leader offering CT scanning, CMM, and 3D X-ray systems used globally for AM part qualification.
Oberkochen, DE
Nikon Metrology
Global supplier of industrial CT, X-ray inspection, CMM, and laser scanning systems for non-destructive evaluation of AM parts.
Tring, GB
Waygate Technologies (Baker Hughes)
Industrial NDT leader — formerly GE Inspection Technologies — offering X-ray, CT, UT, and digital radiography for AM component integrity.
Houston, TX, US
Volume Graphics
German developer of VGStudio MAX — the industry-standard software for CT data analysis, porosity detection, and wall-thickness measurement in AM.
Heidelberg, DE
North Star Imaging
US manufacturer and contract CT scanning service bureau offering micro-focus X-ray and digital radiography for AM part inspection.
Rogers, MN, US
YXLON (Comet Group)
Swiss-German developer of industrial X-ray and CT systems for NDT of AM aerospace, automotive, and electronics components.
Hamburg, CH
diondo — Industrial CT for AM
German industrial CT specialist diondo — d2 and d7 CT systems for non-destructive volumetric inspection of AM components, with large-envelope capabilities for complex metal and polymer parts.
Hattingen, DE
Jesse Garant Metrology Center
North American contract metrology lab specialising in industrial CT scanning services for AM parts, with same-day report turnaround for aerospace and medical.
Windsor, ON / Auburn Hills, MI, US
Relevant standards
Resolution, penetration, and detectability figures from ZEISS, Nikon, Waygate (Baker Hughes), and North Star Imaging published CT specifications (manufacturer tier). Standards per ASTM E1570 / ISO 15708 / VDI-VDE 2630 (CT metrology).
All post-processing