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Looking inside an object without having to change it by opening it or taking it apart: This is the goal of nondestructive testing (NDT). However, only items that fit in the testing device can be scanned. In the GiantEye project, the Fraunhofer Institute for Integrated Circuits IIS is developing an innovative new high-energy computed tomography system at its Development Center X-Ray Technology in Fürth. This system enables nondestructive testing and digitalization of large and complex objects at the highest level of detail.
Traditional industrial tomographs reach their physical limits when it comes to large volumes and high radiography requirements. Fraunhofer IIS's XXL CT system, built in 2013, is considered the world's only publicly accessible facility capable of scanning entire vehicles and freight containers, but this system requires complex handling of the test objects.
Gantry design based on medical CT scanners
The new GiantEye system now goes a step beyond current technology. Unlike its predecessor, the radiation source and detector are supported in a gantry and rotate around the test object in a vertical plane, similar to an oversized medical CT scanner. This enables the examination of large objects in their natural horizontal orientation without having to set them up on one side first. The researchers can thus achieve suitable measurement conditions in highly absorbent zones such as the battery of an electric vehicle. The system eliminates mechanical stresses that could falsify the measurement result or even damage the measured object. “The technology can thus be used for the first time in a production environment, such as in initial production of complex high-voltage battery systems,” says Alexander Ennen, head of the Application-Specific Methods and Systems department at Fraunhofer IIS. The system is to be available for industrial partners in early 2027.
The central technical components of GiantEye are a linear accelerator with an X-ray energy of nine megaelectron volts and a high-precision manipulation as well as a detector system enabling 3D measurement resolutions down to 100 micrometers. The combination of a high-energy X-ray source and robust detectors also enables radiography of thick components and dense materials, such as those found in complete vehicles, high-voltage batteries or aircraft components. The precise manipulation system simultaneously ensures accurate image data with minimal artifacts.
Precise and efficient scanning architecture simplifies handling
A unique feature of GiantEye is the integration of these components in an industrial scanning architecture that combines both precision and efficiency. This system architecture enables the first possible routine CT examination of large objects in an industrial environment without time-consuming preparation. The horizontal gantry design enables shorter measurement times, higher image quality and lower risks for the test objects, especially in safety-critical applications such as the analysis of high-voltage batteries.
The system also opens up a wide range of other possible applications, such as analyzing crash test vehicles, final inspection of additively manufactured components and material diagnostics on large engine components. At the Technical University of Kaiserslautern, the Gulliver CT system has been able to examine concrete beams under load in three dimensions since 2024. This represented a step towards modular applications of large CT portals. “There are also exciting applications in the field of public safety,” explains Norman Uhlmann, Head of the Development Center X-Ray Technology. “A system like this, enabling more detailed insight in the contents of closed transport units without having to open them at great expense, represents a significant technological advance.”
Industrial use possible by early 2027
“We are standing at the threshold of a new technical era and want to make our innovation available worldwide for industrial applications,” explains Giovanni Del Galdo, Fraunhofer IIS director. “Our modular system architecture lets us develop customized solutions for many different testing tasks. This opens up exciting opportunities for a wide range of industries, such as the automotive, aerospace, and energy sectors.”
The researchers are also working to refine data processing and automation in the system. The enormous quantities of data generated by high-energy CT scans require new algorithms for rapid reconstruction and evaluation of 3D images. “Development is also focusing on how to work with the enormous quantity of data. Our goal is not just to build a measuring instrument, but to provide an entire ecosystem for efficient use of the data,” says Ennen. “As soon as routine operations are possible, GiantEye will permanently change quality assurance and product development for large and complex systems.”
https://www.fraunhofer.de/en/press/research-news/2026/march-2026/gianteye-new-di...
Gantry design based on medical CT scanners
Copyright: © Fraunhofer IIS
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Elektrotechnik, Informationstechnik, Maschinenbau, Mathematik, Werkstoffwissenschaften
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Gantry design based on medical CT scanners
Copyright: © Fraunhofer IIS
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