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Building a Cad-Native Digital Twin for Ndt and Plm: Workflow, Tools, and Case Study Cover

Building a Cad-Native Digital Twin for Ndt and Plm: Workflow, Tools, and Case Study

Fatigue of Aircraft Structures
Volume 2024 (2024): Issue 16 (December 2024)
By: Miłosz Sobociński,  Piotr Synaszko,  Krzysztof Dragan and  Jakub Kotowski  
Open Access
|Oct 2025

Figures & Tables

Figure 1.

The damage-tolerance concept for ensuring sufficient service life, proposed by Brot (2012).
The damage-tolerance concept for ensuring sufficient service life, proposed by Brot (2012).

Figure 2.

Demonstration of the flattening effect when an image is collected along a surface (as is the case for UT). It can be observed that the flattening primarily affects the unwrapped surface near the edges.
Demonstration of the flattening effect when an image is collected along a surface (as is the case for UT). It can be observed that the flattening primarily affects the unwrapped surface near the edges.

Figure 3.

Demonstration of the flattening effect, when an image is collected as a projection of the surface (as is the case for TT).
Demonstration of the flattening effect, when an image is collected as a projection of the surface (as is the case for TT).

Figure 4.

Data processing scheme for preparing a digital twin.
Data processing scheme for preparing a digital twin.

Figure 5.

Timeline graphs comparing the time needed to prepare an inspection report.
Timeline graphs comparing the time needed to prepare an inspection report.

Figure 6.

EchoTerm® Thermal Wave Imaging system used to collect TT data images.
EchoTerm® Thermal Wave Imaging system used to collect TT data images.

Figure 7.

Components of MAUS V system. PC (a) and track with trolley, arm and sensor (b).
Components of MAUS V system. PC (a) and track with trolley, arm and sensor (b).

Figure 8.

Demonstration of the point-finding procedure. Reference points are aligned with the center points of the holes. In this example, the searched point is located 310 mm from the left reference point and 205 mm from the right reference point.
Demonstration of the point-finding procedure. Reference points are aligned with the center points of the holes. In this example, the searched point is located 310 mm from the left reference point and 205 mm from the right reference point.

Figure 9.

Points that must be localized on both the 3D digital model and its real counterpart to correctly position UT data on the model.
Points that must be localized on both the 3D digital model and its real counterpart to correctly position UT data on the model.

Figure 10.

Possible sets of points that must be localized on both the 3D CAD model and its real counterpart to correctly position TT data on the model.
Possible sets of points that must be localized on both the 3D CAD model and its real counterpart to correctly position TT data on the model.

Figure 11.

Flow chart presenting the actions that must be performed during inspection.
Flow chart presenting the actions that must be performed during inspection.

Figure 12.

Macros developed to properly position data images.
Macros developed to properly position data images.

Figure 13.

Macro developed for measurements on the model.
Macro developed for measurements on the model.

Figure 14.

Honeywell HTF7000 nacelle. The contour of the tested part is marked with a red line. Original image source: Safran Group (2021).
Honeywell HTF7000 nacelle. The contour of the tested part is marked with a red line. Original image source: Safran Group (2021).

Figure 15.

Inner (a) and outer (b) side of the specimen.
Inner (a) and outer (b) side of the specimen.

Figure 16.

The process of creating a surface for UV mapping and image localization.
The process of creating a surface for UV mapping and image localization.

Figure 17.

UV map created on surface created for result-mapping and projection.
UV map created on surface created for result-mapping and projection.

Figure 18.

Model after post-processing.
Model after post-processing.

Figure 19.

Example of annotations on reference holes.
Example of annotations on reference holes.

Figure 20.

TT results for the tested areas near the points (a) E and H – ID:TT1; (b) H and I – ID:TT2
TT results for the tested areas near the points (a) E and H – ID:TT1; (b) H and I – ID:TT2

Figure 21.

Photographs of UT testing in progress. Test IDs: UT1 (a), UT2 (b).
Photographs of UT testing in progress. Test IDs: UT1 (a), UT2 (b).

Figure 22.

UT results for tested area near the points J and K. Image represents the C-scan. ID:UT1.
UT results for tested area near the points J and K. Image represents the C-scan. ID:UT1.

Figure 23.

UT results for tested area near the points B and C. Image represents the C-scan. ID:UT2.
UT results for tested area near the points B and C. Image represents the C-scan. ID:UT2.

Figure 24.

Steps of TT image projection onto the model. Positioning points were obtained using macro. Example of TT2 projection.
Steps of TT image projection onto the model. Positioning points were obtained using macro. Example of TT2 projection.

Figure 25.

Steps in UT image mapping onto the model. Positioning points were obtained using macro. Example of UT1 mapping.
Steps in UT image mapping onto the model. Positioning points were obtained using macro. Example of UT1 mapping.

Figure 26.

Digital twin with mapped/projected inspection results.
Digital twin with mapped/projected inspection results.

Figure 27.

Decal Sticker folder containing mapped/projected images presented in the form of thumbnails.
Decal Sticker folder containing mapped/projected images presented in the form of thumbnails.
DOI: https://doi.org/10.2478/fas-2024-0012 | Journal eISSN: 2300-7591 | Journal ISSN: 2081-7738
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Language: English
Page range: 161 - 187
Published on: Oct 14, 2025
Published by: ŁUKASIEWICZ RESEARCH NETWORK – INSTITUTE OF AVIATION
In partnership with: Paradigm Publishing Services
Publication frequency: 1 issue per year
Keywords:
Digital Twin,
3D NDT,
CAD,
3D thermography and ultrasonic testing,
defects database,
Product Lifecycle Management
Related subjects:
Engineering,
Introductions and overviews,
Engineering, other

© 2025 Miłosz Sobociński, Piotr Synaszko, Krzysztof Dragan, Jakub Kotowski, published by ŁUKASIEWICZ RESEARCH NETWORK – INSTITUTE OF AVIATION
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 3.0 License.

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