Achieving New Levels of Research Innovation with Metrology Solutions

Established in 1985, the National Institute for Aviation Research (NIAR) at Wichita State University is at the forefront of advancing aerospace, defense and manufacturing technologies.

As a research and development powerhouse with a $400 million annual budget, a 1,500-member team, and nearly two million square feet of laboratory and office space in six locations, NIAR provides cutting-edge research, testing, certification, and training services to the aviation, defense, and manufacturing industries. Located in Wichita, Kansas—known as the "Air Capital of the World"—NIAR supports clients in the private sector and government agencies such as the FAA and the U.S. Department of Defense.

Renowned worldwide for its expertise, NIAR specializes in technology, such as composites and advanced materials, digital twin, and cutting-edge manufacturing methods, such as automation and additive manufacturing.

The challenge: Inaccurate 3D measurements complicate R&D workflows

As NIAR expanded its defense-related digital twin programs, the team encountered issues with 3D measurement accuracy—something the Institute could not compromise on in the highly regulated aerospace and defense sectors.

Traditional methods, including manual techniques and recreating 2D drawings, were no longer adequate for capturing the complex geometries involved in NIAR programs.

For example, team members used to rely on sampling points, which limited the ability to capture complete surface data. Accuracy issues became even more apparent when working on complex work like creating digital twins for aging military vehicles.

Furthermore, the growing scope of NIAR’s projects required portable equipment capable of performing in different environments, from controlled laboratories to rugged field conditions on military bases. Delays caused by inefficient equipment also impacted project timelines.

"In our field, even the smallest inaccuracy can have serious implications. The limitations of traditional methods made it clear that we needed a new approach to 3D measurements," explained Chris Rempe, NIAR Reverse Engineering and Additive Manufacturing Lab manager. “Our main criteria for the metrology solutions we wanted were accuracy, reliability, portability and scalability.”

The solution: Three Creaform 3D scanning solutions for a multi-faceted approach

To overcome these challenges, NIAR chose Creaform’s HandySCAN 3D|BLACK Series, MetraSCAN BLACK+™|Elite optical CMM 3D scanner, and VXmodel scan-to-CAD software.

“We were impressed by the speed of data capture, the target-based referencing to accommodate various environments, compact design, and the fact Creaform’s technologies are ISO-calibrated,” Rempe noted.

The HandySCAN 3D|BLACK Series, a lightweight handheld 3D scanner, offered impressive accuracy levels for scanning both small components and large structures in confined spaces. Its portability allowed technicians to conduct 3D scans directly in the field, eliminating the need to transport parts to a controlled environment.

VXmodel broke new ground in NIAR’s 3D measurement processes. It made it possible for team members to easily carry out reverse engineering tasks by converting scanned data directly into CAD models. It eliminated unnecessary file manipulations, which reduced post-scanning processing times.

Thanks to the user-friendliness of the 3D scanners and software, technicians were quickly onboarded and were creating 3D scans and CAD models in no time flat in VXmodel. “Most technicians feel comfortable with the new equipment after just a few uses. That’s all it takes to get a feel for distance, angles and settings. Some bigger projects can take a bit longer, but the learning curve is relatively short regardless,” Rempe added.

The results: Increased R&D capacity and efficiency

Integrating Creaform’s solutions has significantly boosted NIAR’s research and development efforts, which meant the Institute could take on more ambitious projects. The ability to perform scans directly on-site has streamlined the team’s processes, reduced delays, and improved overall technician productivity. VXmodel software has also simplified the conversion of scanned data into CAD models, helping NIAR to achieve better results more quickly, maintaining the high-quality standards its clients have come to expect.