From Medicine to Manufacturing: CT Scanning is a Transformative Tool for Industry

It’s been said that a picture is worth a thousand words. And the images captured by today’s industrial CT scanning technologies are worth considerably more to manufacturers eager to get products to market.

Since it was first developed for medical use in the 1970s, computed tomography (CT) scanning has become a mainstay in an array of industries. Unlike traditional inspection methods, today’s CT scanning tools capture 100% of internal geometry without damaging the part — examinations that were previously impossible with non-destructive methods.

With today’s CT scanning technology, it is possible to differentiate between multiple materials or multiple components in an assembly.

How It Works

CT scanning does not require any external forces such as pressure or stress to be applied on the part being scanned. Instead, an X-ray source transmits a continuous beam of X-rays through the part. The part is rotated (typically a full 360 degrees) as 2D X-ray images (radiographs) are captured from various angles. By moving the object closer to the X-ray source, its features can be magnified.

The resulting images are reconstructed to create a detailed, digital 3D model of an object’s internal structure. This model can then be visually inspected for leak detection or assembly issues, or processed for further analyses, such as dimensional inspection, porosity analysis, or reverse engineering.

Using powerful CT scanning software tools, data is displayed in a user-friendly, 3D format to aid in visualization and analysis. A color gradient scale makes it easy to see exactly where a part is out of compliance — and potentially why.  Because of the use of X-rays, nothing can hide. This allows 100% data capture and every internal or external feature will be viewable, unlike other line-of-sight scanning methods.

Common Uses for CT Scanning

CT scanning can be used on virtually any sample, from microscopic medical devices to fighter jet components. The ability to drill down and view internal geometries at a granular level is particularly helpful in industries such as aerospace and medical where there is simply no room for error.

Common industrial uses for CT scanning include:

• Assembly Verification
• Leak Testing (Verification of Mechanical Seal)
• Non-Destructive Inspection
• Dimensional Inspection of Internal Geometry
• Capability Studies
• Over-Molded Components
• Void/Inclusion Analysis
• Volume/Surface Area Calculations
• Wall Thickness Analysis
• Reverse Engineering
• Failure Analysis
• Porosity Analysis
• Comparative Analysis (Part-to-CAD and Part-to-Part)
• Solder Integrity Inspection
• Composite Analysis
• Viewing Internal Cracks, Pits & Voids

When (and When Not) to Use CT Scanning

CT scanning is suitable for many materials, including plastics, silicones, rubbers, aluminum, steel, stainless steel, nickel, nitinol, titanium, brass, copper, platinum, iridium, inconel, tungsten, and other exotic metals. It works equally well with organic, thin, and flexible materials that are often difficult to inspect with traditional methods.

However, CT scanning is not an ideal testing method for every type of part. Parts that are very large, made of high-density materials, or have  a very high aspect ratio (wide and thin) provide a challenge when scanned using this method. Radiography (X-ray) is a better choice in situations involving:

• Large volume of parts
• Full production run or individual parts
• Fast analysis of common defects
• Weld analysis
• Dense metals

Benefits of CT Scanning

Compared to other forms of traditional testing, CT scanning offers clear benefits in critical areas like safety, quality and cost control.

• Safety: CT scanning allows for early detection of internal defects that could later lead to major mishaps and failures if left undetected. For example, in the aerospace industry, CT scanning is used to examine wall thickness, erosion and wear of turbine blades to enhance reliability and reduce the risk of in-flight failures.

• Quality: By ensuring the highest quality standards, CT scanning helps manufacturers produce more reliable components that perform as designed.

• Cost Savings: CT scanning provides rapid and comprehensive analysis, significantly speeding up the inspection process, from prototype to production.

For example, when preparing to design or modify a mold, there are tens of thousands, and even hundreds of thousands of dollars, at stake. During the process of designing, redesigning, or reverse engineering injection molds, Westminster Tool uses CT scanning to view critical and non-critical dimensions and perform part-to-CAD comparisons to detect dimensional and feature differences between expected and actual geometry. All of this drastically reduces the number of mold and part iterations and, in turn, saves time and money.

Benefits of Using an Independent Lab

Manufacturers with a frequent need for CT scanning might consider bringing the service in-house to gain greater control over the testing process and costs. However, outsourcing often proves to be the more efficient, cost-effective and flexible option.

When you outsource, you avoid the hefty price tag on today’s CT scanning equipment, and the ongoing costs of facilities, maintenance, calibration and training. In addition, if you purchase CT scanning equipment that will only be used occasionally, you can likely achieve a better return on investment by partnering with a third-party lab, where you pay only for the services you need.

Most important, a leading third-party lab like Industrial Inspection & Analysis (IIA) offers state-of-the-art tools as wel as  NDT and metrology expertise for faster turnarounds and fewer errors.

Why Choose IIA for CT Scanning? 

At IIA, we use the latest tools and technologies — including mobile 3D scanning capabilities — to deliver data you can depend on. We are able to CT scan in super high resolution, and we are continually expanding our capabilities. For example, in 2025 we added the Lumafield Neptune industrial X-ray CT scanner to our toolkit. This state-of-the-art technology allows root cause analysis to be completed in one-third of the time and less than half the cost of traditional technology.

From CT Scanning to non-destructive testing, IIA offers a full range of ISO-accredited lab services to meet your unique needs. We’ve been using CT scanning to help manufacturers perfect their products for decades.

In today’s highly competitive world of manufacturing, CT scanning represents the future of industrial metrology. For CT scanning and more, the team and tools you’ll find at IIA will help you deliver superior products, reduce costs, and maybe even stay one step ahead of the competition.

Learn More About IIA’s CT Scanning Services