Wind Turbine Blade Inspection
Wind turbine blades are massive, multi-layer composites where tiny deviations can cost megawatts. GigaScan delivers fully automated, full-blade inspection that finds what manual checks miss. Then translates measurements into actionable insights with TrueProp.
Blades Are Big. Errors Are Expensive.
Modern turbine blades can exceed 100 meters. Each twist, camber, or microscopic misalignment affects efficiency, accelerates fatigue, and increases risk of field failure. Traditional inspection tools and manual checks struggle at this scale by leaving manufacturers exposed to costly surprises. GigaScan redefines precision for blades of any scale.
Measuring Even the Largest Blades
GigaScan uses extended measurement volumes to capture an entire blade in a single setup, eliminating the need for repositioning or stitching and ensuring seamless, uncompromised results. It delivers high-resolution, repeatable data from root to tip, covering leading and trailing edges as well as all critical transition zones, enabling full-blade capture, precise geometry mapping, and detailed inspection of edge and transition areas.
Keeping Bond Lines Strong and Safe
Bond lines between shell halves and internal components are critical load-bearing interfaces, and any voids, misalignment, or uneven adhesive can undermine structural integrity. GigaScan identifies even the most subtle defects in these areas, enabling manufacturers to verify safety and reliability with confidence. The result is longer service life, fewer field failures, and greater trust in every blade produced. Because, every blade deserves perfection.
Hidden Risks in Manual Inspections
Manual inspection relies on visual checks and hand-held gauges that lack the precision needed for blades spanning more than 80 meters, allowing small waviness, laminate drift, and bond-line misalignment to go undetected until they become costly, time-consuming problems to fix. These limitations make inspection slow, inconsistent, and reactive, leaving unnecessary risk in the manufacturing process.
Full automation with GigaScan provides micron-level precision across complex blade surfaces, delivers repeatable, standardized inspection from shift to shift and factory to factory, and enables high-throughput scanning without repositioning. The system outputs actionable results for QA, production, and engineering teams, ensuring every blade is measured, verified, and fully traceable for consistent, reliable manufacturing.
Partnering with TrueProp for Full Blade Assessment
TrueProp transforms automated scan data into a full, physics-based assessment of each blade. It compares measured geometry against hydrodynamic and structural models, showing how deviations in twist, camber, pitch, or bond-line alignment impact efficiency, load distribution, fatigue life, and overall reliability. Manufacturers use this insight to make targeted corrections, boost reliability, and ensure every blade meets stringent operational requirements, delivering consistent, high-performing components.
How We Make Turbine Blade Quality Checks
Fast and Reliable
Step 1
GigaScan 3D vision system scans the entire turbine blade in a single setup with complete high-precision geometry.
Step 2
Automated checks immediately confirm that every specification is met, preventing errors and reducing inspection time.
Step 3
Scan data is transferred into TrueProp, PLM, MES, and ERP systems for analysis.
Step 4
Engineers receive clear, visual pass/fail reports, enabling fast, accurate, and effective corrective actions immediately.
Step 5
Dashboards track trends, reduce variability, enhance quality, and support faster confident data-driven decisions.
Real Outcomes for Manufacturers
Manufacturers using our turbine blade inspection workflow see fewer late-stage defects and costly rework, tighter process control, and improved aerodynamic performance. The system reduces warranty exposure while generating standardized, auditable datasets that support certification and regulatory compliance giving engineering and quality teams confidence in every blade they produce.
Who Benefits Most
Our inspection workflow is especially useful for blade OEMs scaling to 80–100+ meter formats, Tier-1 suppliers handling bonded assemblies, and QA, production, or engineering teams that need repeatable, traceable measurements.
Experience full-blade inspection in action. GigaScan, combined with TrueProp, brings geometry, quality, and performance together seamlessly.
Want to inspect more turbines than ever without working overtime?