Advanced 3D Laser Scanning Enhances Aerospace and Defense Manufacturing Quality

BOLD Laser Automation—a New Hampshire–based specialist in laser metrology and automation—has reengineered its high-speed, non-contact inspection systems, originally used for food and medical packaging, into tools tailored for aerospace and defense manufacturing. By pivoting from seal‑alignment and fill‑level inspection to detecting surface irregularities, dimensional variances, and assembly misalignments in aircraft‑grade parts like composites and precision-machined fittings, BOLD addresses critical needs in AS9100-compliant production.

Founded in 2018 by industry veterans Todd Lizotte, Orest Ohar, Joe Dagher, and Patrick Buckley—experienced in high-precision laser drilling at companies such as Hitachi—BOLD brings deep expertise in beam shaping and laser process automation.

Throughput, Detection, and Traceability: Metrics That Matter

BOLD’s adapted systems now achieve:

• Over 500 complex part scans per hour—matching aerospace production line speeds
• 99% defect detection accuracy, identifying minute surface flaws, dimensional deviations, and misalignments
• Real-time metrology that enables first-pass validation, reducing costly rework and scrap

These figures position the platform as a robust complement to aerospace quality assurance, helping suppliers maintain consistency and avoid delays that could impact certification and scheduling.

Embedding AS9100 Compliance into Inspection

Designed for integration into AS9100-compliant manufacturing, BOLD scanners log lot and serial data, supplying traceable digital records within MES and ERP systems. This supports audit-ready traceability and proactive management of nonconforming materials—essential for defense sector supply chains.

BOLD’s Laser Metrology Product Line

BOLD offers several purpose-built systems:

• LJS1820S Manual 3D Static Measurement System: Static laser profiler optimized for surface contamination and defect detection in composite panels and optical surfaces.
• CDM1820S Confocal Differential Measurement System: Confocal thickness sensor measuring coatings, films, and multilayer composite layups with micron precision.
• LPMA1000 modular platform: Supports micro-welding, drilling, and skiving with beam diagnostic controls—ideal for processing machined fittings and micro‑fabricated parts.
• PS1016A Mechanical Probe Station: A flexible multi-prober (16 to 64 probes) enabling non-destructive testing across diverse aerospace components.

These systems demonstrate BOLD’s tactical approach—deploying laser metrology where precision meets throughput.

Industry Perspective: Capabilities Aligned with Trends

Aerospace manufacturers are increasingly adopting non-destructive, laser-based inspection—echoed by the rise of CT scanners, vision-guided systems, and structured-light profilometers. BOLD’s offering dovetails with these trends by delivering traceable, real-time analytics that support compliance, quality, and operational efficiency.

Editorial Insight: Integration Defines Success

While advanced scanning can significantly reduce defect rates, its effectiveness depends on integration. Experts emphasize that metrology solutions must be connected to MES/ERP for feedback-driven quality control. BOLD’s design—eschewing over-engineered features in favor of operator-friendly data exports and systems interoperability—positions it for practical deployment.

Envisioning a Smarter Assembly Line

Imagine an aerospace manufacturing line where each composite skin, pressed fitting, or panel passes under BOLD’s laser arrays. A live stream of digital data is generated—annotating deviations, verifying fitment, and logging metrics. Operators monitor dashboards flagging trends, parts out of spec are routed for corrective action, and traceability is inherently built into the process. Scan‑driven automation redefines quality from reactive to predictive.

Strategic Assessment: BOLD’s Aerospace Breakthrough

BOLD Laser Automation’s repurposing of high-throughput laser metrology systems from packaging to aerospace highlights a strategic evolution. By retaining core metrics—throughput, accuracy, traceability—while aligning with AS9100 standards, BOLD reframes inspection as a strategic asset, not a regulatory cost.

Aerospace quality leaders evaluating solutions may find BOLD’s systems compelling: they combine precision, speed, and integration in a cost-effective package. With domain expertise, US-based manufacturing, and tools engineered for real-world production, BOLD stands poised to elevate quality assurance in the next generation of aerospace and defense supply chains.