The Impact of the Top 3 Strategic Imperatives on the Synergizing of the NDT and Dimensional Metrology Industry

Industry Convergence

• Combining precise measurement techniques with non-invasive inspection methods lays the foundation for fully integrated solutions for holistic asset integrity management and quality assurance.

• Though the integration of the 2 disciplines is in the nascent stage, they are being used across all stages of the product development life cycle.
• Industry consolidation with potential partnerships, as well as acquisitions, is anticipated over the next 2-5 years.
• A holistic and versatile solution, computed tomography (CT) will lead this convergence trend.

Disruptive Technologies

• AI/ML, digital twin, and robotics, along with advancements in 3D metrology scanning, 3D CT, phased array ultrasonic testing (PAUT), ground-penetrating radar (GPR), and terahertz imaging, are enhancing these solutions' adeptness.
• These technologies augment the ability to detect, predict, and monitor defects in real time using edge devices.
• The demand for fully automated systems will increase, reducing dependence on skilled inspectors. Alternatively, intelligent AI agents can be created to analyze inspection data and provide insights.
• Virtual twins will simulate and improve manufacturing processes, and robots are being used to carry out inspections in inaccessible areas.

Transformative Megatrends

• The growing interest in sustainability, product quality, and worker safety is paving the way for integrating NDT and metrology.
• The focus on preventing unwanted downtime places greater emphasis on predictive maintenance and asset life cycle management solutions. Integrating metrology and NDT data will drive this solution capability.
• Waste reduction will aid the integration of NDT and metrology. For example, an integrated NDT/metrology solution helps in identifying early-stage quality issues and opportunities for battery recycling.
• As data is central to this process, data management and interpretation is important

Growth Drivers

• The emphasis on quality has evolved significantly over the past decade. New materials and complex designs are becoming the norm in manufacturing industries. Components and parts must comply with standards and tolerances while ensuring reliability. This will spark interest in integrated NDT and metrology solutions.
• Advancements in sensors, optical metrology, automated systems, and 3D scanning technologies, such as X-ray CT, augment the possibility of integrated solutions. For example, CT technology creates high-resolution 3D models that enable material and dimensional analysis. In addition, new NDT techniques, such as PAUT, TOFD, and terahertz imaging, enhance integrated solutions’ capabilities.
• The emphasis on 100% measurement and inspection is growing, as customers strive to maintain higher throughput without a drop in quality. This trend supports the need for automated inspection systems (AIS). AIS coupled with AI/ML enables predictive maintenance capabilities.
• Critical and public infrastructure requires proactive maintenance to avoid mishaps. Both NDT inspections and metrology tools are used for this purpose. Structural health monitoring using a combination of NDT and dimensional metrology enables a comprehensive assessment.

Growth Restraints

• Dimensional metrology and NDT inspection equipment generate data in different formats. Hence, combining data formats for further processing requires data harmonization. Lack of standardization and interoperability between various data sources and vendors will deter adoption during the short term.
• The monetary and operational investment required to implement an integrated software solution with legacy systems and processes is a key hindrance to adoption. The time and costs associated with software licensing, upgrading hardware, customization, and worker training are expected to outweigh the benefits of implementing an integrated solution, especially for small and medium-sized enterprises.
• The shortage of skilled labor in this industry will remain a key challenge. The high costs associated with certifications restrain the introduction of trained professionals. With industry veterans approaching retirement, the supply-demand gap of technicians has increased.

Technology Trends

1. Advanced Imaging and Scanning Technologies These technologies capture assets’ and parts’ point cloud data, enabling high-quality reconstruction and digital comparison with CAD models.
2. Robotics Robotics improves worker safety and efficiency in performing repetitive tasks. It also reduces manual errors while improving operational efficiency.
3. New NDT Techniques Phased-array ultrasonics, time-of-flight diffraction, and terahertz imaging are some new techniques that provide improved sub-surface defect detection capabilities.
4. Digital Twin and AR/VR Virtual twins provide continuous monitoring capabilities, enabling condition-based monitoring of assets, while AR enables remote assistance and collaboration with experts.
5. AI/ML AI helps with automatic defect detection and decision-making while ML aids process optimization.