Hexcel Corporation Uses Metron G2 Laser Scanning System to Help Produce Aerospace Parts

Hexcel's Engineered Products business unit manufactures advanced composites for the aerospace industry. Hexcel products – which include carbon fibers, structural adhesives, honeycombs, pre-pregs, sandwich panels and reinforcement fabrics – are used on virtually every commercial and military aircraft produced in the Western World, and also in thousands of other products.

The Hexcel Engineered Products business, headquartered in Kent, WA, is a major supplier in the aircraft structures and interiors market, designing and manufacturing a broad range of finished components for structural airframes and interiors. Hexcel is one of the largest U.S. producers of carbon fiber; the world's largest weaver of structural fabrics; the number one producer of composite materials; and a manufacturer of composite parts and structures.

The company markets its products to customers in the commercial aerospace, space and defense, electronics, recreational and general industrial markets. Originally established in 1950 as the Heath Aerospace Company, Hexcel's history is one of documented performance for the world's top aerospace and defense contractors, including Airbus, Boeing, British Aerospace, CASA Bombardier, Mitsubishi Heavy Industries, Lockheed Martin and McDonnell Douglas.

3D Inspection and Verification

After extensive evaluation of advanced measuring solutions, the Engineered Products business recently turned to Metron Systems, Inc. to help solve the difficult problem of quickly and accurately measuring complex composite aircraft parts. Measuring complex composite parts is time-consuming with other methods such as coordinate measuring machines (CMM). Quickly identifying how a part deviates from its intended design is important in order to adjust and verify new tools to improve time to market, and to keep production processes flowing smoothly and avoid rework.

Metron Systems had the answers with the G2 Laser Scanner. The Metron G2 Laser Scanner is a fully integrated 3D measurement and analysis system that streamlines the entire quality verification workflow – scanning, point cloud manipulation, comparative analysis and reporting. The system automatically inspects and verifies complex parts in up to 1/10 the time of standard methods.

The G2 enables manufacturers of precision parts to quickly profile and produce 3D images with an accuracy of +/- 0.001 in. and repeatability of 0.0005 in. in the entire scan volume. Parts can be composed of metal, plastic, ceramic, composite or virtually any material with a surface finish from dull matt to highly reflective.

The combination of extended measurement volume and the ability to scan virtually any material or surface, means the G2 can accurately measure a broad selection of parts and products.

• Extended volume (EV) configuration capable of measuring a 24 in. x 24 in. x 24 in. volume, 36 in. x 36 in. x 36 in. volume or 60 in. x 60 in. x 60 in. volume.
• Standard configuration available in 24 in., 36 in., or 60 in. of vertical travel.
• Accurately measures the surface geometry of complex parts and components, including highly reflective surfaces.
• Measures the entire surface of a part rather than just a few selected points.
• Patented optical laser scanning technology and automatic gain control eliminate reflection-based artifacts.

Built-in Tools for Automation

A high level of integrated automation makes the Metron G2 ideal for industrial inspection. An integrated barcode scanner allows the operator to control the scanning and analysis process, while precision pneumatic fixturing guarantees precise placement and rotation of the part under inspection.

Scan data is automatically loaded into an analysis package that compares the data with engineering specifications and quickly reports quality ratings over 100% of the scanned part. Also, scan data from different views or angles are automatically merged. The G2 automatically compares the measured part to the CAD model and displays deviations in color according to magnitude.

A suite of analysis tools allows sophisticated studies such as cross sectional/2D analysis, or measurement of critical features and dimensions. A user-specified report is automatically generated for each part.

Richard Alkire, Quality Systems Manager for Hexcel's Engineered Products is enthusiastic about the Metron G2 Laser Scanner.

"The Metron System has become an integral part of the design and production process here at Hexcel," he says. "We are able to quickly and accurately measure our composite parts, improve our time to market, reduce rework and enhance our production processes."