Non-destructive testing (NDT) makes it possible to analyse the interior of components without opening or dismantling them. This method is indispensable, especially for complex and safety-critical systems. However, conventional industrial computed tomography systems quickly reach their physical and technical limits when dealing with large objects. With the GiantEye research project, the Fraunhofer Institute for Integrated Circuits IIS at the Development Centre for X-ray Technology in Fürth is now developing a high-energy CT system that is set to raise the bar for the examination of large and complex structures.

Further development of XXL CT technology

Back in 2013, Fraunhofer IIS commissioned a globally unique XXL CT system that can scan entire vehicles or even freight containers. This system is considered to be the only publicly accessible facility of its kind. However, handling the test objects is complex, as large components often have to be fixed in special positions.

With GiantEye, research is now taking a decisive step forward. The new system is based on a gantry design familiar from medical computed tomography. In this design, the radiation source and detector rotate around the test object in a vertical plane. This allows large components to be examined in their natural horizontal position without having to be laboriously set up or rotated beforehand.

This architecture enables significantly better measurement conditions – especially in highly absorbent areas such as the battery modules of electric vehicles. At the same time, mechanical stresses that could distort measurements or damage the test object are reduced. This makes the technology suitable for use in industrial production environments for the first time, for example in the initial testing of complex high-voltage battery systems.

High-energy X-ray technology for large structures

At the heart of the system is a linear accelerator with an X-ray energy of nine megaelectron volts. In combination with a high-precision manipulation system and powerful detectors, GiantEye enables three-dimensional measurement resolutions of up to 100 micrometres.

This combination of a high-energy source and robust detectors allows particularly dense or thick materials to be X-rayed. This means that even complete vehicles, aircraft components or large energy and drive systems can be examined non-destructively. At the same time, the precise positioning technology ensures high image quality and minimises artefacts in the CT data.

Industrial scan architecture for routine use

A special feature of the GiantEye system is the integration of all components into an industrial scan architecture that enables both precision and efficiency. The horizontal gantry design allows test objects to be scanned faster and handled more safely at the same time.

This makes routine CT examination of large objects in industrial production processes realistic for the first time. This makes quality inspections significantly more reliable, especially in safety-critical applications such as high-voltage batteries.

Wide range of applications

In addition to battery technology, there are numerous other possible applications. These include the analysis of crash test vehicles, the final inspection of additively manufactured components and material analyses on large engine components.

Large-scale CT technology is also being further developed in other research projects. For example, the Gulliver CT system at the Technical University of Kaiserslautern has been examining concrete beams under load in three dimensions since 2024. Such developments demonstrate the potential of modular large-scale CT systems for various scientific and industrial applications.

In addition, researchers also see prospects in the area of public safety. High-performance CT systems could, for example, analyse the contents of closed transport containers much more accurately without having to open them at great expense.

Start of industrial use from 2027

The development of the GiantEye system encompasses not only the hardware, but also the processing of the enormous amounts of data generated by high-energy CT scans. New algorithms are intended to enable faster reconstruction and automated analysis of the three-dimensional image data.

Fraunhofer IIS’s goal is not only to develop a measuring device, but also to provide a complete technological ecosystem for the efficient use of CT data. The first industrial applications are expected to be possible from the beginning of 2027.

According to the researchers, GiantEye could trigger a fundamental change in quality assurance and product development for large technical systems in the long term – especially in industries such as automotive, aerospace and energy technology.