Achieving a Perfect Fit for Aerospace Component Integration with 3D Scanning

Designing a custom component for integration within an aircraft poses unique challenges when space is limited. Once installed, the new element must fit perfectly with the surrounding geometry and the overlying top panel. Even the slightest dimensional deviation could compromise both the functionality and aesthetics of the assembly.

 

 

Challenges:

How to integrate a custom-designed component within an environment with extremely limited space?

To design a new component with a perfect fit, it is essential to accurately capture the geometry of the environment—including the surrounding surfaces and cable routing zones—and to generate a precise CAD model that serves as the foundation for the design. This approach ensures that the new component not only meets tight tolerances but also fits perfectly once installed.

What limitations come with using traditional measuring tools and manual data acquisition?

Manual data acquisition is inherently slow and prone to error, with clear limitations in both accuracy and repeatability. In some cases, the geometric complexity or surface characteristics of the parts make it impossible to achieve the required level of accuracy.

What negative consequences would an aerospace company want to avoid when designing custom components?

The company could be unable to verify certain critical tolerances, which might compromise the quality and functionality of key components. In aerospace environments, the ability to compare measurement data from designed parts with CAD models or technical specifications is essential to ensure that components meet the required tolerances.

In addition, the need to generate detailed technical reports to demonstrate component conformity and maintain full traceability of measurement data throughout the product life cycle further reinforces the importance of adopting a more accurate measuring solution.

Solution: Accurate, Portable, and Intuitive 3D Scanning Solutions

Accuracy

To meet the stringent requirements of the aerospace industry, the solution needs to capture highly accurate and repeatable 3D measurements of intricate geometries and complex surfaces. Professional-grade 3D scanners achieve this level of accuracy consistently—regardless of the measurement setup quality or the user’s experience level.

 

 

Portability

Relying on triangulation with optical reflectors to determine their position relative to the part, handheld 3D scanners operate as fully stand-alone devices—no tripod or external tracking system required. Compact enough to fit into a small suitcase, they can be easily transported and used anywhere, even in challenging environments, without compromising accuracy.

Ease of use

Thanks to its intuitive software interface, the solution is easy to operate and allows for quick onboarding. Technicians can begin using it effectively soon after purchase and, with additional training, gradually unlock its full potential.

Equipped with both 2D sketching and 3D modeling functionalities, the software enables design engineers to sketch and model directly on scan data. Moreover, its parametric transfer to SOLIDWORKS allows easy design edits and feature-driven modeling, simplifying designs through the transfer of real, editable CAD models.

 

 

The HandySCAN 3D and Creaform’s reverse engineering software module, Scan-to-CAD—part of the Creaform Metrology Suite—are perfect examples of accurate, portable, and intuitive 3D scanning solutions.

Benefits: Enhanced Control and Design Capabilities for Higher-Quality Components

With the addition of a 3D scanner to its measurement toolkit, an aerospace company can improve its control processes and design capabilities. The new solution can reduce errors and accelerate design processes—ultimately ensuring better-quality aerospace components.

Profitable Investment in Time and Money

A professional-grade 3D scanner provides the aerospace company with the flexibility to handle both model design and dimensional control tasks. Having a single tool capable of multiple functions represents a cost-effective investment. With only one system to learn, users can confidently perform a wide range of applications—streamlining training and maximizing the return on the device.

Error Minimization

With 3D scanning, manual data acquisition is completely eliminated. Complex geometries and challenging surfaces can now be measured with high accuracy. The resulting dimensions serve as a reliable foundation for designing new components, giving engineers the confidence that each part will fit perfectly within tight spaces—leaving virtually no margin for error.

Better Quality

With a 3D scanner, the aerospace company can confidently verify critical tolerances that might otherwise have compromised the quality and functionality of key components. Measurement data from designed parts can be easily compared with CAD models or technical specifications, ensuring that every component meets the required tolerances.

Client: Europavia

For over 60 years, Europavia has been supplying spare parts, equipment, and maintenance services to the armed forces and state security agencies, specializing in supporting the full life cycle of their systems.

The company is dedicated to MRO logistics management, aeronautical equipment maintenance, and the promotion and distribution of advanced technology and systems across Spain’s aeronautics, defense, space, and infrastructure markets.

Through close collaboration with leading international manufacturers, Europavia provides state-of-the-art technological products that complement the national aerospace and defense industries. With its EASA-certified maintenance center, the company has expanded its capabilities to include engineering and manufacturing services, offering complete integration solutions.

Europavia makes use of the HandySCAN 3D in solutions to support design, engineering, and maintenance processes within aeronautical platforms.