Xarion’s Dry, Contact-Free NDT Method Closes Automated Ultrasonic Testing Gap

Why It Matters

By removing coupling media and probe contact, LEA reduces integration costs and expands automated NDT to hard‑to‑reach, low‑volume aerospace components, boosting safety and operational efficiency. The flexibility of LEAbot also accelerates MRO cycles, lowering labor and downtime for airlines and defense fleets.

Key Takeaways

• LEA provides dry, contact‑free ultrasonic testing using laser and optical microphone
• No gel or probe contact cuts cost, enables hard‑to‑reach inspections
• LEAbot on a cobot automates scans for small batches and MRO tasks
• Pulse‑echo mode delivers depth‑resolved defect data from a single‑side scan
• Used by a major European aerospace OEM for automated tail‑boom inspections

Pulse Analysis

Nondestructive testing (NDT) has long relied on liquid‑coupled ultrasonic probes that demand surface preparation and direct contact, limiting automation in aerospace and defense. Xarion’s Laser Excited Acoustics (LEA) overturns this paradigm by generating ultrasound with a pulsed laser and detecting it with an optical microphone, creating a completely dry, contact‑free inspection process. This breakthrough removes two major barriers—coupling media and probe pressure—allowing manufacturers to integrate ultrasonic inspection into high‑speed production lines without costly infrastructure or extensive part handling.

The practical impact is evident in the aerospace sector, where a leading European OEM now uses LEA to scan helicopter tail‑boom carbon‑fiber structures. The compact, fiber‑coupled probe can be mounted on a robotic lance and inserted into confined honeycomb sections, delivering high‑resolution images without water or gel. By pairing the sensor with a collaborative robot, the LEAbot forms a mobile inspection cell that can be redeployed within minutes, making it ideal for low‑volume series, mixed‑fleet MRO, and parts with variable geometries that would otherwise require manual, labor‑intensive checks.

Beyond accessibility, LEA’s pulse‑echo mode supplies depth‑resolved defect information from a single‑side scan, a capability previously limited to through‑transmission setups. Engineers can now pinpoint the exact ply of a delamination in carbon‑fiber composites, informing precise repair strategies and reducing unnecessary part replacements. As the industry pushes toward greater automation and tighter safety standards, LEA’s flexible, cost‑effective platform positions Xarion as a key enabler of next‑generation NDT, likely accelerating adoption across automotive, defense, and broader manufacturing sectors.