A ZEISS 3D scanning system captures data from the exterior surface of an aircraft inside a brightly lit hangar.

STRUCTURAL DENT EVALUATION

How to Speed up Aircraft Dent Inspection

Designed for MRO teams: an automated dent detection app that combines 3D mapping with detailed documentation.

Significant time savings by minimizing manual effort
Traceable results without user interpretation
Export compatible with dent & buckle records

A bottleneck in modern MRO: inefficient dent evaluation

Accurate and consistent dent inspection is a critical part of every Maintenance, Repair, and Overhaul (MRO) process. Even minor surface deformations can impact structural integrity, disrupt aerodynamic performance, lead to unplanned downtime, or raise compliance concerns. Therefore, each aircraft comes with a structural repair manual specifying how dents must be assessed from fuselage to wingtip, including tolerances based on depth, size, and location.

Currently, dent inspection typically follows a manual workflow: dents are measured with gauges or measuring tapes, checked against tolerances, and entered by hand into the dent & buckle chart. This cumulative log must stay complete and traceable throughout the aircraft’s life cycle.

Time-consuming process

The manual workflow involves multiple tools, several measurements per dent, and manual calculations — all of which consume valuable turnaround time during tightly scheduled maintenance. The evaluation relies on the inspector's interpretation and transferring the data into reports manually introduces errors.
Surface complexity

On curved or multi-contour surfaces, precise measurement point acquisition is challenging — especially under difficult lighting conditions. Consequently, manual measurements can be highly inaccurate.
No traceability

There is no continuous data flow from measurement to evaluation, tolerance comparison, and final reporting. This lack of seamless integration results in fragmented records, making it challenging to track measurement data history.

Our solution: Dent Check

Automate your aircraft dent inspection and evaluation with the Dent Check app for ZEISS INSPECT. The software significantly speeds up damage assessment and ensures compliance with aviation maintenance standards.

3D surface inspection image showing color-coded depth deviations analyzed with ZEISS INSPECT software, alongside a data table of measurement results.

MRO dent inspection app

Get precise results using 3D scans

Dent Check enables MRO teams to digitally detect, measure, and document dents in 3D, reducing manual effort and minimizing aircraft downtime.

The workflow is straightforward: The aircraft is digitized using a portable 3D laser scanner. Inspection tolerances are set directly in the Dent Check app. The app automatically analyzes and classifies all surface features, such as dents or erosion, based on established airline or OEM guidelines. Inspection features include depth, length, width, area, and dimensional ratios (length-to-width, width-to-depth).

Similar to manual workflows, dent positions are referenced relative to surrounding frames and stringers, ensuring spatial accuracy for compliance and traceability.

Your benefits

Precision and efficiency – built into every step.

Microscopic image showing numerous green and red circular markers with contour lines, captured using ZEISS imaging technology.

Quick results

Dent Check automates the analysis and reporting process, significantly reducing inspection time compared to manual gauge-based methods.

3D surface scan with color mapping and multiple dent analysis checkpoints displayed using ZEISS inspection software.

Advanced reporting

The reports give a clear and concise picture of inspection results, including color-coded visualizations. The results can be exported directly to a spreadsheet application, making integration into existing dent & buckle charts seamless.

ZEISS software interface displaying dent check parameters alongside a 3D surface scan of a textured metallic component.

Improved accuracy and repeatability

Software-based analysis removes human subjectivity and error, ensuring consistent and reliable results.

Surface topography analysis image showing measurement points, contour lines, and data tables generated by ZEISS inspection software.

Traceable outcomes

Every dent is clearly documented — with position, dimensions, and evaluation criteria — creating a fully traceable inspection history. This ensures compliance, simplifies audits, and supports lifecycle integrity.

3D scan image showing dent inspection results with measurement data and labeled check points, generated with ZEISS INSPECT 2025.

All-in-one software

Dent Check is an app for ZEISS INSPECT Optical 3D software that analyzes surface defects on scanned objects. It provides inspectors with a comprehensive tool, presenting results in a unified report. The app's intuitive interface allows for quick user adoption with minimal training.

Digitize the fuselage with a portable, hand-held 3D scanning system.

Used by major aerospace companies, ZEISS scanners are compliant with NADCAP standards and represent the gold standard for inspection systems in the industry.

However, for analyzing data with the Dent Check app, you are not limited to a ZEISS system – you can acquire your measuring data with any scanner generating STL files.
Create your dent check with required inspection features and individual tolerances. The software automatically positions each dent on the Dent Check Map according to user-defined frame and stringer references.
The software automatically analyzes all selected features and highlights out-of-tolerance values with red flags — making critical issues instantly visible.
With one click, the software exports all dent data in a spreadsheet format, using a familiar heatmap layout tailored to industry standards.

Suitable for other applications

Dent Check, initially developed for aviation MRO, is versatile across various industries. The app can be utilized for any situation requiring precise dent or erosion analysis.

Aerial view of a network of large industrial pipelines running above ground through a grassy area.

Oil & gas

In pipeline systems, dents and surface anomalies caused by ground movement, mechanical impact, or pressure variation pose serious integrity risks. Early detection and assessment are critical to ensure operational safety and prevent costly structural damage.

Close-up view of an offshore wind turbine with several other wind turbines in the background over the ocean under a clear sky.

Wind energy

Surface erosion, especially along the leading edge of turbine blades, is often caused by rain or ice particle impact. If not inspected and addressed, such damage can reduce performance and lead to long-term structural issues.

Get started now with Dent Check

Looking to digitize and automate your dent measurements? Dent Check is available as an app for ZEISS INSPECT.

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How to Speed up Aircraft Dent Inspection

A bottleneck in modern MRO: inefficient dent evaluation

Key challenges in manual dent inspection and assessment

Time-consuming process

Surface complexity

No traceability