High-Precision Laser Scanning for Aircraft, Aerospace Parts, and Facilities

Aerospace 3D Laser Scanning Services

3D Laser Scanning for Aerospace

For nearly 20 years, Arrival 3D has been a trusted provider of advanced 3D scanning, metrology, and precision measurement services to companies in both commercial and military aerospace sectors. From compact mechanical components to full-scale aircraft, we deliver reliable, high-resolution scan data to support inspection, reverse engineering, FAA compliance, and space planning.

Aerospace systems are complex—filled with electronics, hydraulics, pneumatics, and tight-tolerance assemblies. That’s why our team applies industry-specific expertise to recommend the most effective solution, whether it’s in-house equipment consulting or on-site scanning services. Our track record includes scanning over 30 different aircraft, providing detailed CAD models and digital twins for manufacturing, maintenance, and certification workflows.

Whether you’re designing new systems, upgrading aircraft, or verifying as-built conditions, Arrival 3D offers the accuracy and experience to help you make confident, data-driven decisions.

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    Aerospace Applications We Support

    Aerospace 3D Scanning & Modeling Applications

    • Reverse Engineering of Aircraft Components – Capture complex geometries of structural and mechanical parts—such as landing gear, wing assemblies, engine mounts, and nacelles—to create CAD-ready models for part reproduction, design improvement, or legacy support.
    • Tooling, Jigs & Fixture Validation – Validate aerospace tooling and assembly jigs with high-precision 3D scans. Identify dimensional deviations early and compare against design intent using tolerance analysis and digital inspection tools.
    • As-Built Documentation for Hangars & Plants – Document large aerospace facilities—such as hangars, R&D labs, and manufacturing floors—with accurate point clouds and 3D BIM models. Improve space utilization, equipment layout, and renovation planning.
    • Interior & Cabin Scanning – Scan aircraft interiors including cockpits, cabins, galleys, and cargo holds to support interior retrofits, seating reconfiguration, and inflight systems design.
    • Maintenance, Repair, and Overhaul (MRO) – Use 3D scan data to support maintenance planning, fit checks, and on-site inspections. Reduce aircraft downtime and improve service accuracy with digital references for real-time decision-making.
    • R&D, Prototyping & Simulation – Capture prototypes, composite structures, and experimental designs to generate digital twins for simulation, stress analysis, and performance testing in CFD or FEA environments.
    • Helicopters, Drones & UAV Systems – Model drone frames, rotor systems, and small aircraft structures for aerospace startups and defense innovators. Ensure compliance and improve speed-to-market with precise 3D data.
    • Defense & Aerospace Compliance Documentation – Generate accurate digital records for government, military, and defense applications. Our scans support FAA compliance, airworthiness inspections, and configuration management of mission-critical assets.

    Accurately Capture Complex Shapes to Produce CAD Drawings

    There are a great variety of different parts and objects that can be scanned including: molds, tools, jigs, fixtures body panels and even complete aircraft. If you don’t have digital 3D drawings of your tooling, or any drawings at all, 3D scanning is a way to capture them and preserve their shape using precise 3D scanning technology. No prior 3D experience is required for you to start taking advantage of 3D scanning. Output files are provided in neutral standard formats that you can provide to your engineers to utilize. 

    How accurate are the results?

    3D scanning is typically accurate to within +/- .005 for most applications, but depending on which scanner is used, accuracy in the .001″ range is achievable.  We select the most efficient 3D scanning method that can meet your minimum accuracy requirement. By identifying the least amount of accuracy that you can live with, we can optimize the process to save you money. 

    3D laser scan of powered parachute
    3D laser scan aircraft
    Entire Aircraft
    3D laser scan aircraft
    Landing Gear Hardware
    3D laser scan aircraft
    Access panel

    Why Do Aerospace Companies Use 3D Scanning?

    Aerospace companies rely on 3D laser scanning and metrology for its precision, speed, and ability to capture complex geometries—especially when dealing with legacy parts, tight tolerances, or regulatory requirements. Here are some of the most common reasons:

    • Archiving Molds, Fixtures & Tooling
      Preserve and digitally store critical manufacturing assets that may be difficult to replace.

    • Documenting Hand-Built or Legacy Designs
      Capture as-built conditions of custom or legacy parts that were originally made without CAD data.

    • Reverse Engineering Undocumented Parts
      Scan and convert physical parts into 3D models when technical drawings no longer exist.

    • FAA-Certified Repair & Replacement Parts
      Support FAA repair stations by generating accurate digital models for part repair or reproduction.

    • Part Duplication & Reproduction
      Quickly duplicate worn or damaged components with precision-matched geometry.

    • Modern Manufacturing (e.g., 3D Printing)
      Adapt legacy parts to new manufacturing processes like additive manufacturing.

    • Inspection & Quality Control
      Compare manufactured parts to original CAD designs to ensure dimensional accuracy.

    • Certification & Compliance Drawings
      Generate the technical documentation and drawings required for regulatory approvals.

    • Simulation & Engineering Analysis
      Use scan data to build models for FEA (Finite Element Analysis) or CFD (Computational Fluid Dynamics) simulations.

    • New Mold or Tool Creation
      Create new molds or forming tools based on existing components when retooling is required.

    In short, 3D scanning in aerospace accelerates design cycles, ensures precision, supports compliance, and reduces costs, making it a vital tool across engineering, maintenance, and manufacturing teams.

    3D laser scan aircraft
    3D laser scan of aircraft service cart
    jet 3D scanning services - Arrival 3D
    Airplane Assembly Factory Floor | 3D Laser Scanning Services Help Reduce Aircraft Assembly Costs
    3D Models

    What Can You Do with a 3D Model Created by Reverse Engineering Services?

    A 3D model produced through reverse engineering is more than just a digital replica—it’s a powerful asset with a wide range of practical applications across manufacturing, engineering, and product development.

    Thanks to the high accuracy and quality of the models, they can be used in:

    • CNC Machining & Injection Molding – Manufacture new parts using the digital file as a production-ready template.

    • 3D Printing – Rapidly prototype or recreate components using additive manufacturing technologies.

    • Design Modifications – Edit or optimize the original geometry to improve performance or adapt to new applications.

    • 2D Drawings & Schematics – Generate dimensioned drawings directly from the 3D model for documentation or fabrication.

    • Exploded Views & Animations – Create visual presentations or animations for training, manuals, or marketing purposes.

    • Digital Comparisons – Compare the scanned part against a CAD model or another scan for quality control or wear analysis.

    • Design Mating Parts or Enclosures – Use the model as a base for designing parts that must fit or interact with the original.

    • Global Manufacturing – Send the digital file to suppliers or manufacturers overseas, avoiding shipping physical prototypes.

    • Long-Term Archiving – Keep a digital backup of rare, obsolete, or custom parts for future reference or reproduction.

    Once an object has been converted into a precise 3D model, the possibilities are virtually limitless. Whether you’re streamlining production, preserving legacy parts, or accelerating product development, reverse-engineered models unlock maximum flexibility and long-term value.

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