Zeiss Rotor Blades

Rotor Blade Inspection

Advanced optical technologies for efficient rotor blade inspection

Helicopters and other rotary-wing aircraft rely on rotor blades for lift and control. Rotor blades operate in harsh environments, and while accurate manufacture ensures best performance, they often suffer minor damage in service. Manufacturing defects can lead to premature blade replacement or worse, and blown debris causes damage in the real world. There are key benefits to OEMs and suppliers in being able to measure manufacturing quality and the consistency of modifications, and to the rapid, accurate assessment of blade condition in use.

Advanced optical technologies for efficient rotor blade inspection


Helicopter rotor blades are complex, aerodynamically-shaped components. With airfoil profile, twist, sweep and bow can be extremely challenging for traditional techniques, they are difficult to measure with tactile solutions or static optical sensors. Automated, flexible 3D measurement systems are therefore the way to measure them accurately and quickly. This way, manufacturing defects may be identified early on, helping eliminate uncertainty about component assembly and speeding production.

Zeiss Rotor Blades Maintenance, Repair and Overhaul

Maintenance, repair and overhaul

Lifting and controlling the machine in poor weather, dust and sand, helicopter and other rotary-wing aircraft rotor blades have a tough time. Damage and on-condition inspection can ground an aircraft for a full or partial blade change, work that costs not only money but also mission readiness. With the ATOS ScanBox Series 7, OEMs and MROs have the option of automatically scanning complete rotor blades. Where removing the blade is undesirable, or only a partial scan is required, then the ATOS 5 offers the flexibility of robust hangar-floor metrology. Together, ZEISS 3D measurement systems fulfil traditional inspection needs while enabling faster inspection cycles. Advanced inspection processes showing and mapping surface defects, and measuring the airfoil profile, are also easily available.

Zeiss Rotor Blades Research & Development

Research & development

ZEISS´s ATOS 3D sensors and ARAMIS Digital Image Correlation system are essential tools for research and development organizations designing blades, molds and tooling, redefining manufacturing processes, updating materials data and validating simulations. The ATOS 3D scanners bring rapid, accurate capability to the reverse engineering, prototyping, mold validation molds and first article inspection processes. Meanwhile, ARAMIS provides dynamic tracking for materials characterization – bending, tensile and fatigue testing, and more – typically in a universal testing machine, and supports structural trials on larger assemblies, including load limit testing validation, fatigue and vibration testing.

The solution

ZEISS ATOS 3D metrology systems are capable of creating a Digital Twin (or virtual copy) of a rotor blade, offering high resolution and repeatability with a fast turnaround time. Advanced ATOS hardware and intelligent software allow repeatable, precision measurement enabling accurate production and modification design. Helicopter OEMs and suppliers are increasingly using ZEISS optical 3D sensors to make rotor blade manufacture and inspection more efficient, assuring quality and improving safety.

  • The solution
Zeiss Rotor  Solutions

ATOS ScanBox Series 7 + ATOS 5

The ATOS ScanBox Series 7 equipped with the powerful ATOS 5 is the answer to measuring large aerostructures efficiently and accurately. This automated piece of metrology performs complete analysis measurements on large volume parts (up to 6 m) while the ATOS 5 visualizes hidden errors by capturing high-precision data in rapid time. Complete with 8-axis kinematics, the ATOS ScanBox Series 7 allows high flexibility in positioning the ATOS 5 thanks to its 8 degrees of freedom. The ATOS 5 has a powerful built-in light source that captures high-precision data with 0.2 seconds per scan and 100 frames per second. Thanks to its industry-leading camera sensors and projection technology, the ATOS 5 requires fewer individual scans and thus accelerates the entire measuring procedure.

ATOS solutions provide

  • For manufacturing

    • Automated, operator-independent inspection
    • High resolution and high throughput metrology-grade measurements
  • For MRO

    • NDT (and non-contact) inspection
    • Building Digital Twin for smarter maintenance
  • For research & development

    • Design validation
    • Rapid turn around of evaluations

The trusted testing solution, turning data into profitable insights

  • Zeiss Rotor Blades
ARAMIS hardware & software

ARAMIS hardware & software


ARAMIS is ZEISS’s upgrade from strain gauges and displacement sensors; a stereoscopic 3D optical sensor capable of measuring 3D strains and displacements. ZEISS’s software suite can rapidly analyse test data for easy validation of structural simulations, providing a quicker process with less testing iterations.The results enable users to review and improve simulation parameters, as well as optimize current and future design processes. Therefore they can reduce the number of costly test runs and consequently speed up product development. At the same time, the results show insights into safety risks, part durability, as well as creep and aging processes. This increases not only the safety, but also the lifetime of products.

ARAMIS solutions provide

  • Flexible systems

    Physical capabilities to capture complex geometries

  • Real-time inspection

    Instant measurement of deformations and strain

  • Faster, relevant data

    Rapid data capture outpaces standard contact sensors

  • Optimized setup

    Accelerated test setup with comprehensive software

Kontakt aufnehmen

Möchten Sie mehr über unsere branchenspezifischen Lösungen erfahren? Wir stehen Ihnen gerne für weitere Informationen oder eine Demo zur Verfügung.

Benötigen Sie weitere Informationen?

Nehmen Sie Kontakt mit uns auf. Unsere Experten werden sich bei Ihnen melden.

Formular wird geladen ...

/ 4
Nächster Schritt:
  • Interessensabfrage
  • Persönliche Angaben
  • Unternehmensangaben

Wenn Sie weitere Informationen zur Datenverarbeitung bei ZEISS haben möchten, lesen Sie bitte unsere Datenschutzhinweise.