A Multibeam 3D Non-Destructive Inspection System for Aircraft Evaluation

Nondestructive inspection (NDI) technicians in the Air Force play a critical role in detecting what others cannot see, ensuring aircraft and equipment remain mission-ready, safe, and operational. Their expertise in uncovering hidden structural flaws prevents catastrophic failures, safeguards Airmen, and sustains Air Force dominance in the skies. These Airmen use highly specialized equipment to inspect equipment both on and off aircraft. Inspections are designed to avoid potentially catastrophic structural failure of key components that control the flight dynamics of the aircraft, ensure the weapons systems operate appropriately, and even ensure the pilot can safely eject should they need to. The Air Force needs a more robust approach to non-destructive evaluation (NDE) for its aging fleet of aircraft. Current state-of-the-art 2D X-ray NDE images are often not clear and full of background noise from the flat display of a target aircraft part. The limitations of the current technology are leaving a critical element of our nation's warfighting capability grounded. In fact, according to recent reporting from Air & Space Forces Magazine Air Force fully mission capable (FMC) rates were the lowest in almost 20 years in fiscal year 2024 at 67.15%. It is no secret the Air Force has an aging fleet of aircraft. With the average age of 29 years, those flight hours result in significant structural wear. In fact, there are two airframes over 60 years old: the KC-135 Stratotanker and the B-52 Stratofortress. The only way these aging airframes can survive is if our technicians have the best possible vision into the integrity of the critical components.