NASA uses industrial CT scans to find microscopic cracks in rocket parts before launch.

Industrial Computed Tomography (CT) is a cornerstone of NASA's non-destructive evaluation (NDE) process, managed largely through the Marshall Space Flight Center. Unlike medical CT scans, industrial versions use much higher energy X-rays to penetrate dense aerospace alloys and composite materials. This technology allows engineers to create 3D models of internal structures with a resolution of just a few microns.The importance of this technology was highlighted during the development of the Orion spacecraft and the Space Launch System (SLS). For instance, the heat shield on the Orion capsule is composed of Avcoat, a material that must be perfectly bonded to its titanium substrate. NASA uses CT scanning to ensure there are no voids or delaminations that could lead to structural failure during the intense 2,760°C heat of atmospheric re-entry.In 2015, NASA researchers published findings on using high-resolution CT to inspect 3D-printed rocket engine parts. Because additive manufacturing can leave internal pores or 'lack-of-fusion' defects, these scans are the only way to verify part integrity without cutting the component open. This rigorous testing protocol has significantly reduced the risk of catastrophic engine failures during the critical ascent phase of missions.