AEROSPACE MANUFACTURING

The Aircraft. And Its Twin.

Where Physical Meets Digital

The Digital Thread Starts at the Hole.

Defense and aerospace programs are building Digital Twins of entire aircraft, production lines, and sustainment fleets. But a Digital Twin is only as accurate as the data feeding it. Aeroscan delivers 260,000 LNE-certified data points per hole — the verified geometric foundation your digital thread depends on, from first drill to final depot inspection.

$50.7B

Digital Twin Market in Aerospace & Defense by 2034

37.5%

CAGR 2025–2034

40%

Large Organizations will Integrate Digital Twin by 2027

A Virtual Replica is Only as Good as its Data.

A Digital Twin is a dynamic, living virtual replica of a physical asset, system, or process — continuously updated with real-world data to enable simulation, prediction, and optimization across the full product lifecycle. For aerospace and defense manufacturers, Digital Twins are no longer aspirational. Leading primes have deployed them across production facilities to track manufacturing progress in real time, detect quality deviations at drilling and milling stations, and anticipate maintenance needs before they impact the line.
The U.S. defense sector is investing heavily — driven by the recognition that programs which build verified digital records from the start will have decisive advantages in sustainment, upgrades, and lifecycle cost management. But every Digital Twin has a foundational requirement: trusted, high-density, objective data at the component level. For airframes, that starts at the fastener hole.
A single fighter aircraft program involves tens of thousands of fastener holes drilled across aluminum, CFRP, titanium, and steel. Each hole is a structural and aerodynamic data point affecting fit, function, fatigue life, and flight safety. Traditional manual inspection delivers one or two spot measurements per hole — subjective, operator-dependent, and impossible to audit. That data cannot feed a Digital Twin. It simply disappears.
Aeroscan replaces that process entirely — generating 260,000 objective, timestamped data points per hole, in seconds, from a single handheld device. Every measurement is certifiable. Every scan is traceable. Every hole becomes a verified digital asset.

From the Floor to the Digital Thread.

Aeroscan Powers Every Phase of the Digital Twin Lifecycle — from Initial Design Validation through Sustainment and MRO

01

Design Validation

High-density hole geometry data feeds directly into virtual models — enabling engineers to validate tolerances and refine designs with real manufacturing data, not assumptions. Anomalies detected and mapped across thousands of holes inform future drill specifications, tolerancing decisions, and material stack configurations. Every program makes the next one better.

02

Manufacturing Efficiency

Real-time scan data flags deviations the moment they occur — no manual logging, no delayed quality reports. Production keeps moving with objective quality records at every station. Aeroscan now delivers hole-level drilling intelligence, detecting quality deviations and predicting equipment failures before they occur.

03

Predictive Maintenance

Aeroscan tracks drill bit degradation scan by scan — mapping cutting tool wear across every hole in the sequence. Replacement needs are forecast before defects occur and before the line stops. Fewer surprises. Lower rework costs. Higher throughput across the full production cycle.

04

Audit-Ready Traceability

Defense and aerospace programs operate under strict documentation requirements. Every hole Aeroscan scans is automatically logged — geometry, deviations, surface anomalies, timestamps — creating an immutable quality record that meets compliance requirements across production, delivery, and sustainment. No manual data entry. No transcription errors. No gaps in the record.

05

Lifecycle MRO

The digital record created during initial production doesn't expire. The same verified hole geometry that drove production quality decisions supports depot-level repair validation, tolerance verification, and sustainment planning decades later. Aeroscan establishes the geometric baseline that makes true lifecycle management operational — giving MRO teams objective data to work from rather than assumptions about original condition.

06

Program-Wide Collaboration

A single source of objective hole data eliminates disagreements between engineering, quality, and production. Everyone works from the same verified measurements — accelerating decisions, reducing rework loops, and compressing the feedback cycle between the factory floor and the design office. Across multinational programs with complex supply chains, that shared data standard is a significant operational advantage.
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Build the Thread Today. Win Tomorrow.

The aerospace and defense industry is in the middle of a digital transformation that won't wait. Leading primes are building Digital Twins of entire aircraft, production lines, and sustainment fleets — and the programs that don't have verified component-level data from the start will be playing catch-up for the life of the program. Aeroscan is how you get ahead of it. One device. 260,000 data points per hole. A complete digital record from day one.

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One Scan. A Complete Digital Record.

Aeroscan delivers 260,000 data points per hole in seconds — cutting inspection time by up to 80% and generating millions in documented program savings.