CASE STUDY
Complex Aircraft Structural Damage Assessment
The Challenge
Following a severe storm, an aircraft sustained extensive structural damage when the roof of a hangar collapsed onto its fuselage. The impact caused widespread dents, scratches and gouges to the external skin panels, alongside deformation of internal structural components, including frames and stringers.
With damage affecting both external surfaces and internal structures, a comprehensive and accurate assessment was essential to establish the full extent of the damage and develop an effective repair strategy. The complexity of the repairs, including skin panel replacements, patch repairs and structural splices, required precise dimensional information to support engineering decisions and minimise aircraft downtime.
Our Solutions
MES mobilised a rapid-response engineering team, arriving on site within 24 hours of the initial call.
Using advanced 3D laser scanning and digital metrology, our engineers captured detailed dimensional data of both the external fuselage skin and internal structural components. This enabled us to accurately identify and quantify surface damage, assess structural deformation and establish the relationship between damaged and unaffected areas.
The resulting high-resolution scan data provided a comprehensive digital representation of the affected structure, allowing engineers to evaluate damage beyond what could be established through conventional visual inspection and manual measurement alone.
The Outcome
MES delivered a rapid, comprehensive assessment of complex aircraft structural damage, providing critical dimensional information to support the development and execution of the repair strategy.
Combining rapid deployment, high-accuracy 3D scanning and engineering expertise enabled a clearer understanding of the damage, more confident repair decisions and improved coordination between inspection and repair activities.
The result was a more efficient, data-driven approach to complex structural repair planning, helping minimise unnecessary work and reduce aircraft downtime.