Comparative CT Scanning for Component Qualification

The patent creates digital twins (virtual copies) of physical components through CT scanning. These digital models capture the exact geometry, materials, and features of qualified components. Once a component is physically qualified through traditional methods, its digital twin can be used to rapidly evaluate subsequent components without repeating the full qualification process, dramatically reducing lead time while maintaining reliability assurance.

The patent performs preliminary CT scanning and digital modeling of components during the qualification phase. This advance preparation creates a digital reference library that can be immediately used for rapid evaluation of future components. The preliminary action of creating these digital models eliminates the need for repeated physical testing and documentation, reducing qualification lead time for subsequent components.

The patent replaces extensive physical documentation with digital CT scan models. The three-dimensional digital twins contain all geometric, material, and feature information that would otherwise require pages of documentation. These digital models serve as the quality record, eliminating the need for manual measurement reports, dimensional verification documents, and material certification paperwork, thus reducing documentation complexity while maintaining quality assurance.

The patent substitutes manual measurement and inspection processes with automated CT scanning. The CT system automatically captures precise dimensional data, material composition, and internal features, replacing manual calipers, micrometers, and visual inspection procedures. This automation reduces the complexity of quality documentation by generating digital records directly from the scan data without requiring manual data entry and processing.

The patent enables different qualification approaches for different components based on their criticality. Non-critical components can be rapidly evaluated using digital twin comparison with minimal inspection, while only critical components require full traditional qualification. This localized quality approach maintains reliability for essential components while dramatically increasing overall productivity by reducing qualification requirements for less critical parts, thereby expanding the eligible supplier base.

The patent implements a tiered qualification approach where components receive partial qualification through digital twin comparison rather than complete traditional qualification. For components that are similar to already-qualified parts, a simplified evaluation process using CT scan data comparison provides sufficient assurance without requiring the full rigour of traditional qualification. This partial action approach increases productivity and expands supplier options while maintaining adequate reliability levels.