GE Aerospace Launches Robotic White Light Inspection for Engine Maintenance

This article is based on an official press release from GE Aerospace.

GE Aerospace Deploys “White Light” Robots to Revolutionize Engine Maintenance

In a significant move toward automating the Maintenance, Repair, and Overhaul (MRO) sector, GE Aerospace has unveiled a new robotic inspection system designed to alleviate the physical burden of inspecting critical jet engine components. Dubbed the “Dance of the White Light Robots” for the synchronized movement of its dual robotic arms, the technology was deployed in late 2024 at the company’s Services Technology Acceleration Center (STAC) in Cincinnati, Ohio.

According to the company, this system utilizes high-definition optical scanners and Artificial Intelligence (AI) to inspect High-Pressure Turbine (HPT) disks, components that operate in the hottest, most stressful sections of an aircraft engine. The technology represents the culmination of a five-year joint development effort between GE Aerospace Research in Niskayuna, New York, and the Global Automation and Robotics Center in Bromont, Quebec.

From “Caveman Style” to Digital Twins

Prior to the introduction of this automated workstation, the inspection of HPT disks was a manually intensive process. Technicians relied on flashlights and mirrors to visually scrutinize every millimeter of the complex metal disks to identify scratches, dents, nicks, or corrosion. This method, while effective in the hands of skilled experts, was physically taxing and prone to human fatigue.

Sam Blazek, a Services Technology Leader at GE Aerospace, described the stark contrast between the traditional methods and the new automated workflow:

“Staring at the same part or feature for eight to 12 hours a day can make your head hurt… [we used to inspect] caveman style, by hand. We’re not trying to replace humans with this technology. We want to replicate them.”

The new system addresses these limitations by employing two articulated industrial robots that move in a pre-programmed, choreographed path over the engine part. Instead of lasers, the robots project white light patterns onto the surface to capture precise 3D topographical data. An AI algorithm then analyzes this data in real-time to detect defects that might be invisible to the naked eye.

Creating a Permanent Digital Record

One of the primary advantages of the white light system is its ability to generate a “digital twin” of the component. Unlike a human inspection, which typically results in a binary pass/fail decision or a repair order, the robot creates a comprehensive digital map of the part’s condition. This data is stored for future reference, allowing engineers to track specific wear patterns across a fleet of engines over time.

Jon Hootman, Engineering Director at STAC, emphasized the value of this data consistency in the company’s official statement:

“My ability to have high-quality, consistent, repeatable mapping of the inspection results on a specific part is the magic. It’s the enabler to simplify the programming and logic for all sorts of post-inspection automation opportunities.”

Operational Impact and Efficiency

The deployment of this technology at STAC serves as a proving ground before global rollout. The facility functions as an incubator for scaling MRO technologies. While specific speed metrics for this particular robot remain proprietary, GE Aerospace noted that similar AI-driven tools, such as the Blade Inspection Tool (BIT), have reduced inspection times by up to 50%.

By automating the data collection phase of inspection, GE Aerospace aims to shift the role of skilled technicians from repetitive observation to complex decision-making. The system flags potential defects, but human experts retain the authority to make the final “disposition” on whether a part requires repair or replacement.

AirPro News Analysis

The introduction of white light robotics at GE Aerospace highlights a critical trend in the aviation industry: the shift from reactive to predictive maintenance amidst a tightening labor market. The MRO sector currently faces a shortage of skilled technicians; automating high-fatigue tasks is essential to preserving the workforce.

Furthermore, the creation of “digital twins” for legacy engine parts marks a significant leap in asset management. By digitizing the physical state of HPT disks, airlines and MRO providers can theoretically predict component failures before they occur, moving beyond simple scheduled maintenance. This technology also lays the groundwork for fully automated repair chains, where data from the inspection robot could directly guide automated cleaning, blending, or coating machinery.

Frequently Asked Questions

What is “white light” scanning?
White light scanning, also known as structured light scanning, projects a known pattern of light onto a surface. The system calculates the depth and surface information by analyzing how the pattern distorts when it hits the object, creating a highly accurate 3D model.

Does this robot replace human inspectors?
No. According to GE Aerospace, the goal is to replicate human observation capabilities while eliminating physical fatigue. The robots handle the data collection and initial screening, allowing human technicians to focus on complex decision-making and repairs.

Where is this technology currently used?
The system was first deployed in the fall of 2024 at the Services Technology Acceleration Center (STAC) in Cincinnati, Ohio. It is primarily used for inspecting High-Pressure Turbine (HPT) disks.

Sources

• GE Aerospace