GiantEye – High-Energy CT for the Inspection of very large Objects

The transition to electromobility has fundamentally changed the requirements for inspection technology in the automotive industry. Modern high-voltage batteries consist of countless cells integrated into complex carrier structures made of metal and plastic. Safety-relevant properties such as precise cell positioning, the homogeneity of intercell foams, and the integrity of the joining technology are no longer directly accessible after a pack has been assembled. At the same time, packs are growing into such large assemblies—particularly in cell-to-pack and cell-to-chassis architectures—that complete non-destructive inspection using conventional CT systems is no longer feasible.

GiantEye addresses this challenge on multiple levels. In crash and impact analysis, penetration depths can be quantified, cell damage can be localized, and structural integrity can be assessed—including effects such as elastic spring-back that would be lost during disassembly. For example, after a drive-over test on a battery pack, it was possible to demonstrate that only the absorber layer was deformed while the cells remained undamaged—providing directly usable data for residual safety assessment and simulation validation. During production ramp-up, GiantEye supports the verification of manufacturing processes: the pore structure of intercell foams, cell positioning, and weld and adhesive joints can be fully inspected in 3D without having to destroy samples.

In lifecycle testing, non-destructive CT enables before-and-after comparisons over the entire service life. A begin-of-life scan serves as a reference; after loading, variance analyses reveal changes such as cell swelling or material fatigue and correlate them with the applied load profiles.

In the prototype and architecture phase, the inspection of complete vehicles in road position provides a holistic view: nominal-actual comparisons against CAD, packaging conflicts, generational differences, and the generation of digital twins become possible in a single measurement.

In aerospace, large-volume components, safety-critical functions, and exotic material combinations converge. Engine housings can be fully inspected for porosity, cracks, or inclusions without the need for disassembly. For additively manufactured large components, whose internal channel structures and layer bonds can only be inspected volumetrically, GiantEye also makes components accessible that exceed the build volume limits of conventional CT systems.

Structural components made of composite materials can be examined for delaminations, adhesive bond defects, or impact damage. In the MRO sector, the system complements established inspection methods with a complete 3D condition assessment of large components – applicable for lifetime assessment and damage evaluation reports. Furthermore, landing gear components with complex internal geometries and high material density can be fully penetrated by X-ray inspection.

Computed tomography has become an established tool in museum research. In contrast to industrial applications, the focus is on the non-destructive exploration of objects that must under no circumstances be damaged. CT makes the interior visible without altering the original and provides a complete digital twin. As soon as objects become larger, are embedded in dense materials, or consist of highly diverse materials, conventional CT systems reach their limits. Here, the XXL-CT of the EZRT has established itself as an indispensable tool – and with GiantEye, the gantry design and the ability to scan objects in their natural position open up additional possibilities.

Three projects illustrate the spectrum:

In the 3D-Cipher project, around 60 historical cipher machines were scanned together with the Deutsches Museum and made accessible as open data – the encryption mechanics were documented for the first time without opening the exhibits. For the Roman segmental armor from Kalkriese, a 500 kg block of earth was penetrated with high-energy CT in 1,500 individual exposures. The result: the oldest preserved segmental armor of this type, whose quality fundamentally revised previous assumptions about Roman armor technology.

In the T-rex project, a 66-million-year-old skull embedded in sandstone was tomographed for the Naturalis Biodiversity Center before preparation. The data enabled anatomical recording, revealed hidden fractures, and allowed true-to-original 3D-printed reproductions.

Large-volume objects of technological history also fall into this field: the capture of a nearly six-meter-long Messerschmitt Me 163 made constructive details visible that would have been lost during disassembly. With GiantEye, capturing objects in their natural position becomes possible for the first time – relevant for objects with movable components or pressure-sensitive materials.