Advanced surface inspection for complex aerospace geometries
Antonio Catelluccio & Ryan Torres
Marotta, founded in 1943, provides a fully integrated solution for the aerospace and defense sectors. It designs, develops, qualifies, and manufactures innovative systems for the industry.
Sensofar’s 3D optical profiler, when applied to Marotta’s products, highlights the compelling value of an expanding range of practical applications that transcend traditional industry boundaries.
Marotta Controls required a multifunctional surface roughness evaluation solution, including non-contact precision measurement capabilities for surface roughness analysis, surface flaw detection with dimensional assessment, and the flexibility to capture 3D measurements for complex product geometry. In addition, the system needed to support dimensional evaluation of critical features and 3D rendering analytics for reporting purposes.
Due to the specialized nature of our products and the difficulty in accessing certain features, the S neox Five Axis configuration was selected, integrating Confocal, Interferometry, and Ai Focus Variation technologies. This configuration provides the resolution and flexibility required to meet all these measurement needs within a single platform.
The Sensofar system’s implementation revealed an immediate demand for contactless surface measurements across numerous projects. By leveraging this technology, Marotta engineered specialized fixtures that enable the simultaneous evaluation of multiple components, significantly accelerating manufacturing throughput and fulfillment timelines compared to traditional single-unit contact (profilometer) measurements.
MEASUREMENTS
Representative of sample applications, including void and scratch detection, electroless nickel plating, and a mold scan, were used to demonstrate the capabilities of the S neox Five Axis system and its applicability across space, naval, and power industries.
Void & Scratch detection
The exploration of additional dimensional measurement approaches using the S neox Five Axis revealed new inspection possibilities. Among the most relevant capabilities is the measurement of layer thickness, enabling reliable validation across different applications.
Electroless nickel plating
To evaluate the thickness of an electroless nickel plating sample, the Sensofar S neox Five Axis with Confocal scanning technology was used. This approach provides high-quality visualization and enables comprehensive multidimensional assessment.
This methodology also enables the evaluation of precision internal radius specifications ranging from approximately 51 to 76 µm. These features were assessed using a specialized mold compound technique to capture partfeature impressions, followed by formal inspection using a 2D vision system. A single direct scan enabled four critical dimensions to be reported in a single consolidated report.
Mold Scan
SensoMAP was used in combination with the S neox Five Axis to analyze the mold surface. This software enables sample mirroring and radius profile extraction, allowing clear differentiation between a round radius and a chamfer.
Geometric dimensioning and tolerancing assessment present no challenge. Diameter runout measurements were successfully obtained, showing agreement with Coordinate Measuring Machine data to within approximately 51-76 µm. Thread inspections included pitch-diameter verification and flankangle form deviation analysis.
Surface roughness and burr evaluation
The analyzed sample (E_2) exhibited an average roughness (Ra) of 0.127 µm, indicating high surface quality and controlled material finishing.
The corresponding 3D topography and grayscale intensity images further illustrate the system’s ability to combine quantitative roughness assessment with detailed non-contact surface visualization.
The capabilities of Sensofar S neox Five Axis and the SensoMAP software have proven instrumental in addressing measurement challenges that were previously difficult to overcome. The system enables depth evaluation, thread geometry characterization, radial deviation measurement, and GD&T inspection.
The sample examples presented demonstrate the visual versatility and dimensional diversity of Sensofar’s 3D optical profiler when applied to Marotta’s products, highlighting the compelling value of an expanding range of practical applications that transcend traditional industry boundaries.
Sensofar’s systems support innovation across both experimental and production environments, delivering consistent value in daily operation. The selected system, S neox Five Axis configuration, has enabled measurable growth, driven by evolving manufacturing requirements and the continuous pursuit of deeper dimensional insight.
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