Surface Roughness Inspection on Complex Aerospace Surfaces Using High-Resolution 3D Scanning

Executive Summary

Accurate surface roughness measurement is essential for high-performance aerospace components, where even microscopic surface irregularities can impact efficiency, fatigue life, and safety. EDM Intelligent Solutions delivers advanced, non-contact 3D metrology solutions that enable micron-scale surface characterization on complex geometries, without risking damage to the part. This report presents a real-world application of surface roughness measurement using our MVi5 3D Metrology Center on a precision engine component.

Overview of 3D Metrology Capabilities

Our high-resolution 3D scanning systems provide full surface data sets, allowing precise extraction of form, waviness, and roughness parameters. Surface roughness measurement quantifies the frequency and amplitude of micro-level peaks and valleys within a material’s surface, providing critical insight into wear behavior, friction properties, and coating effectiveness.

Key capabilities include:

Non-contact, high-resolution surface scanning
µm-scale form and roughness data extraction
Surface profile analysis on freeform and complex geometries
Digital archiving and reporting for traceability

Application Case Study: Surface Roughness Inspection

Component Overview

Type: Engine Component
Material: Nickel Alloy
Metrology Service: Surface Roughness Measurement

Four-Step Surface Roughness Inspection Process

Step 1: High-Resolution 3D Scan

Using the MVi5 3D Metrology Center, a full scan of the engine component is performed. The scan captures surface topography with sub-micron resolution, even on complex, curved surfaces.

Step 2: Surface Profile Extraction

Cross-sectional surface profiles are extracted from the 3D data set. These profiles follow the true contours of the component geometry and are used to isolate the areas of interest for roughness analysis.

Step 3: Roughness Parameter Calculation

Standard roughness parameters such as Ra (average roughness), Rz (peak-to-valley height), and others are calculated directly from the extracted profiles. This approach allows for highly localized inspection on specific surface regions.

Step 4: Visualization & Reporting

Roughness data is visualized using 3D maps and profile plots. A comprehensive report is generated with statistical summaries and conformance to engineering specifications.

Results & Value Delivered

Non-destructive, high-accuracy surface roughness analysis
Reliable data collection from complex or freeform surfaces
Enhanced quality assurance and validation of manufacturing processes
Traceable inspection records with detailed 3D visualization

Conclusion

3D surface roughness inspection represents a critical capability in the evaluation of aerospace components, particularly those made from advanced materials such as nickel alloys. EDM Intelligent Solutions’ non-contact metrology systems enable accurate, repeatable, and detailed analysis of complex parts—ensuring reliability, performance, and compliance with the highest industry standards.

About EDM Intelligent Solutions

EDM Intelligent Solutions is a trusted provider of advanced machining and metrology services. Specializing in precision electrical discharge machining and high-resolution 3D inspection, our team supports mission-critical industries such as aerospace, medical, and defense through innovation and quality excellence.