Engineering a Rugged Handheld Inspection Device for Aerospace Applications
Designing the AeroCheck 3 for Performance, Reliability and Usability in the Field
Developing handheld inspection equipment for aerospace and industrial environments requires far more than technical capability alone. The product must be robust, intuitive to use and engineered to perform reliably in safety-critical conditions.
Cambridge Design Technology (CDT) supported the development of the AeroCheck 3, a dual frequency Eddy Current Flaw Detector designed for demanding aerospace inspection applications. The project focused on creating a rugged, ergonomic and production-ready handheld device that could support advanced inspection functionality while improving usability and durability in the field.
The result is a compact instrument that combines high-performance inspection capability with a robust enclosure engineered for real-world use.
Designing for Safety-Critical Environments
The AeroCheck 3 is used in environments where reliability is essential, including aircraft maintenance and inspection. In these settings, every design decision matters — not only for product performance, but also for operational safety.
To reduce the risk of foreign object debris in sensitive areas such as aircraft engines, the product incorporated features including captive screws and locking connectors, helping to ensure that no loose parts could be left behind during use. The instrument also needed to be waterproof, impact resistant and compliant with electromagnetic compatibility (EMC) regulations, while remaining easy to handle during long inspection periods.
Ruggedisation Through Advanced Enclosure Design
A key part of CDT’s role was the development of a completely new enclosure around existing internal components, including PCBs, displays and mounting features, all within very tight size constraints.
The final AeroCheck 3 weighs just 1.15kg yet delivers the ruggedness needed for harsh inspection environments. CDT used a blended polymer housing with over moulded rubber features to improve grip, increase impact resistance and integrate sealing directly into the product design. This advanced over moulding approach not only improves durability but also creates a more secure and comfortable handheld feel for gloved and ungloved users alike.
Ergonomics Built for Real-World Inspection
Handheld NDT equipment must be comfortable, intuitive and practical to use in the field. CDT developed the AeroCheck 3 with a strong focus on ergonomics, ensuring it could be handled confidently for extended periods by both left- and right-handed operators.
Features such as over moulded grip surfaces, rear moulded support bars and a detachable hand strap all contribute to improved handling. The product is also available with either a standard keypad or thumbwheel configuration, giving users the option of faster single-handed navigation and adjustment during inspection.
Combined with a clear menu structure and quick-access functions, these design choices help streamline operation without compromising performance.
Supporting Advanced Inspection Capability
While CDT’s focus was on the mechanical and product design, the enclosure had to support a highly capable inspection platform. The AeroCheck 3 offers dual frequency Eddy Current performance from 10Hz to 20MHz, together with rotary drive C-scan capability as standard and a range of advanced inspection features.
The design also had to accommodate industry-standard probe connectors, allowing compatibility with reflection, bridge and absolute probes from multiple manufacturers. By improving connector access and integrating practical features such as tripod mounting and harness anchor points, CDT helped ensure the final product was as usable in the field as it was capable technically.
Turning Complex Requirements into a Manufacturable Product
The AeroCheck 3 demonstrates CDT’s ability to translate complex engineering, ergonomic and compliance requirements into a manufacturable handheld product.
From safety-led design features and ruggedised over moulded construction through to ergonomic handling and compact packaging, the project required a careful balance of performance, durability and usability. The result is a handheld inspection device designed not just to function, but to perform reliably in the demanding environments for which it was built.
Partner with CDT
If you are developing a handheld device, industrial instrument or specialist product that needs to combine advanced performance with rugged, user-centred design, Cambridge Design Technology can support your programme from concept through to production.
Explore CDT’s Industrial Design and Development and Mechanical Design capabilities to see how their multidisciplinary team can help bring complex technical products to market.
