Composite Material Inspection Systems

STARMANS DIO 2000 Multichannel Automated Ultrasonic Testing

Advanced Composite Inspection Technology

The STARMANS DIO 2000 Multichannel System represents the pinnacle of automated ultrasonic testing technology for composite materials. Specifically engineered for aerospace and advanced manufacturing applications, this system delivers comprehensive through-transmission C-scan inspection with unmatched precision and reliability.

Aerospace-Grade Precision

Composite materials in the aerospace industry demand the highest levels of quality assurance. The DIO 2000 system provides critical defect detection capabilities that meet the stringent requirements of aerospace manufacturing and maintenance operations.

Advanced Inspection Capabilities

Through-Transmission C-Scan Technology

Comprehensive Composite Analysis

• Multi-Channel Operation: Simultaneous inspection across multiple channels for enhanced productivity
• High-Resolution Imaging: Detailed C-scan visualisation of internal composite structures
• Familiar Results Format: Output compatible with conventional ultrasonic testing standards
• Advanced Signal Processing: Optimised algorithms for composite material characteristics

Air-Coupled & Dry-Coupled Methods

Flexible Inspection Approaches

• Air-Coupled Testing: Non-contact inspection eliminates surface contamination concerns
• Dry-Coupled Options: Enhanced coupling for challenging composite configurations
• Versatile Configuration: Adaptable to various composite geometries and thicknesses
• Clean Operation: No coupling gels or liquids required for most applications

Specialised Composite Applications

Aerospace Industry Focus

Mission-Critical Inspection

• Aircraft Components: Wings, fuselage panels, control surfaces, and structural elements
• Engine Components: Composite fan blades, nacelles, and housing components
• Interior Components: Cabin panels, overhead bins, and decorative elements
• Maintenance Inspection: In-service component evaluation and damage assessment

Production Quality Control

Manufacturing Integration

• Real-Time Inspection: Automated quality control during composite manufacturing
• Process Monitoring: Continuous assessment of production quality
• Defect Classification: Intelligent analysis distinguishes between defect types and severity
• Statistical Process Control: Data-driven quality management and trend analysis

Advanced Detection Technologies

Plate Wave Configuration

Simplified Quality Assessment

• Go/No-Go Testing: Binary quality decisions for production environments
• Pultruded Composite Specialization: Optimised for continuous fiber composite products
• High-Speed Inspection: Rapid assessment suitable for production line integration
• Cost-Effective Screening: Efficient pre-screening before detailed analysis

Comprehensive Defect Detection

What the DIO 2000 Detects:

• Delaminations and disbonds
• Porosity and void content
• Foreign object inclusions
• Fiber misalignment and wrinkles
• Thickness variations
• Impact damage and barely visible impact damage (BVID)
• Manufacturing defects and inconsistencies

Multichannel System Advantages

Enhanced Productivity

• Parallel Processing: Multiple inspection channels operating simultaneously
• Increased Throughput: Faster inspection times compared to single-channel systems
• Automated Operation: Reduced operator intervention and consistent results
• Integrated Data Management: Comprehensive inspection records and analysis

Superior Accuracy

• Multi-Perspective Analysis: Multiple channels provide comprehensive defect characterisation
• Cross-Validation: Channel comparison enhances detection reliability
• Advanced Algorithms: Sophisticated signal processing optimised for composite materials
• Calibration Standards: Traceable calibration for aerospace quality requirements

System Configuration & Integration

Flexible Setup Options

Adaptable to Manufacturing Environments

• Production Line Integration: Seamless incorporation into existing manufacturing workflows
• Standalone Operation: Independent inspection stations for quality laboratories
• Portable Configurations: Mobile systems for field inspection and maintenance
• Custom Configurations: Tailored solutions for specific composite inspection requirements

Advanced Control Systems

• Automated Scanning: Programmable scan patterns for various component geometries
• Real-Time Visualisation: Live C-scan imaging during inspection
• Data Analysis Tools: Comprehensive analysis software for defect characterisation
• Report Generation: Automated reporting for quality documentation

Industry Applications

Primary Markets

• Aerospace Manufacturing: Commercial and military aircraft production
• Defense Contractors: Composite armor and structural components
• Automotive Industry: Carbon fiber automotive components
• Marine Industry: Composite hull and structural inspections
• Wind Energy: Turbine blade inspection and quality control
• Sports Equipment: High-performance composite product testing

Inspection Types

• Incoming Material Inspection: Raw composite material verification
• In-Process Quality Control: Manufacturing stage inspection
• Final Product Verification: Completed component validation
• In-Service Maintenance: Periodic inspection and damage assessment
• Research & Development: Material characterisation and development support

Quality Assurance & Compliance

Aerospace Standards Compliance

• AS9100 Compatible: Meets aerospace quality management requirements
• NADCAP Approved: Compliant with aerospace special process requirements
• Traceable Calibration: Reference standards for consistent performance
• Documentation Ready: Complete inspection records for regulatory compliance

Why Choose STARMANS DIO 2000?

Aerospace Heritage: Developed specifically for the demanding requirements of aerospace composite inspection with deep industry expertise.

Proven Technology: Established track record in critical aerospace applications worldwide with demonstrated reliability and accuracy.

Advanced Engineering: Multichannel architecture provides superior inspection capabilities compared to conventional single-channel systems.

Complete Solution: Integrated hardware, software, and support for seamless implementation in manufacturing and maintenance environments.

Elevate your composite inspection capabilities with aerospace-grade technology. Contact Hylec Controls to discuss your specific requirements and discover how the STARMANS DIO 2000 can enhance your composite quality assurance processes.