NDT of filigree and large fiber composite components.

- Mobile. Fast. Versatile. -

Fiber-reinforced composites combine high strength with low weight, offering outstanding mechanical performance. They enable structures that are lighter, more powerful, and more durable than ever before.

Camera tomography enables material inspection regardless of the specific composite type - whether CFRP, GFRP, or NFRP. It works contact-free and is suitable for virtually any geometry, including:

• Flat laminates

• (3D) Sandwich components

• Cylindrical winding structures

• Complex-shaped parts (as shown below)

Even the smallest defects can significantly affect the structural integrity and service life of a component. TENTA camera tomography detects:

• Air inclusions

• Delaminations

• Resin accumulations

• Fiber fractures

• Microcracks

• Bonding defects

The system identifies stiffness inhomogeneities with nanometre sensitivity. Based on this, not only can defects be located, but the actual stress distribution within the fiber bundles can also be made visible. This enables correlation with FEA simulations, providing an optical verification of the real-world stress paths.

Simulated stress path with crack and resulting stress peak in a CFRP fiber bundle vs. nanodeformation with a concentration at the crack.

The following use case illustrates the fast, mobile deployment of the TENTA system during the inspection of a complex fiber-based seat structure: The "BMW M Visionary Material Seat" (Altair ENLIGHTEN AWARD winner, consortium: AMC, BMW M GmbH, csi, DITF, Lasso, Gradel).

In a special winding process (i.e. “xFK in 3D”), fiber bundles are wrapped around free-floating bushings, forming a truss-like, load-optimized geometry.

Due to the cylindrical, glossy black fibers, visual inspection becomes unreliable. At the same time, the part’s geometric complexity limits the applicability of traditional NDT methods like X-ray or ultrasound.

TENTA overcomes both challenges in one: A cobot-guided inspection head (by Kassow Robots) is mounted on a mobile column directly on the shopfloor. Based on CAD data, the robot navigates to 17 defined inspection points in just ~40 seconds. The entire front and back of the part is scanned optically, fully automatically.

Each inspection takes ~1 second, using only eye-safe light and no contact. If the system detects a deviation or anomaly, it stops immediately – enabling the operator to assess and digitally acknowledge the finding (e.g. for repair decisions).

Automated inspection of a wound composite structure using the TENTA camera tomography system. Critical fiber bundle defects are highlighted in red - detected in real time and without contact.

Beyond automated inspection, the TENTA system is also ready for manual, mobile use in labs, production halls, or directly on-site. The sensor is mounted on a standard tripod, aligned, and can scan inspection areas up to 720 mm × 360 mm.

A manual excitation unit introduces slight thermal stress (ΔT = 2 to 3 K), triggering internal deformation. The subsurface inspection is activated at the press of a button.

For example, on large wind turbine blades, the structural integrity of the sandwich can be assessed directly. Defects are located and repaired on-site – and digitally documented afterwards.

Field deployment of the mobile inspection system: damaged fiber bundle highlighted in red